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Materials Engineering Research Institute, Sheeld Hallam University, City Campus, Howard Street, Sheeld S1 1WB, UK
Structural Integrity Research Institute of the University of Sheeld (SIRIUS), Department of Mechanical Engineering, The University of Sheeld,
Sheeld S1 3JD, UK
c
Instituto Technologico de Tlalnepantla, Tlanepantla Edo. de Mex., 54070, Mexico
Received 12 June 2003; received in revised form 23 December 2003; accepted 19 January 2004
Abstract
A methodology dedicated to the optimisation of the fatigue properties of aluminium alloys by controlled shot peening is presented. Selection of the peening conditions is made out of the use of the Design of Experiment and the Eects Neutralisation
Model. Both techniques allowed the optimisation both in terms of life and crack growth rates. Experimental determination and
further analysis of the residual stress relaxation patterns revealed that at high stress levels, low cycle fatigue, life improvement is
predominantly due to slow crack growth rates, while in high cycle fatigue the extension of life is attributed to a prolonged period
of crack arrest.
# 2004 Elsevier Ltd. All rights reserved.
Keywords: Controlled shot peening; Fatigue life; Residual stresses; Surface roughness
1. Introduction
Engineering components and structures are regularly
subjected to cyclic loading and they are consequently
prone to fatigue damage. In most cases, fatigue damage will initiate at the surface due to localised stress
concentrations caused by machining marks, exposed
inclusions or even due to the contrasting movement of
dislocations [1]. Evidently, control over the initiation
and early propagation of surface cracks is paramount
for prolonging the fatigue life of components.
Shot peening is extensively used for the above purpose as it produces near surface plastic deformation
leading to the development of work-hardening and
high magnitude compressive residual stresses [24].
Work hardening is expected to increase the ow resistance of the material and thus reduce crack tip plas
Corresponding author. Tel.: +44-114-225-2457; fax: +44-114-2255390.
E-mail address: c.rodopoulos@shu.ac.uk (C.A. Rodopoulos).
0142-1123/$ - see front matter # 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijfatigue.2004.01.003
850
Nomenclature
a
a
b
b
r
r1
r1
r2
rarrest
rarrest
rFL
a
D
i
Kt
mi/m1
Zi
Notch depth
Normalised notch depth
Notch half width
Normalised notch half width
Far-eld applied stress
Crack closure stress
Dynamic crack closure stress
Flow stress
Crack arrest stress
Dynamic crack arrest stress
Endurance limit
Crack length
Average transverse grain size
Number of half grains
Elastic stress concentration
Grain orientation factor
Vallelanos notch fatigue parameter
Fig. 1.
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Al
0.05
0.5
3.84.9
0.30.9
1.21.8
0.1
0.25
0.15
Bal.
heat-treated at 435 C and naturally aged to a substantially stable condition. Microstructural analysis according to ASTM E112 [10] revealed that the material has a
pancake shape grain structure with an average grain
size of 220, 80 and 52 lm in the longitudinal, transverse and thickness direction, respectively.
Prior to the machining of the fatigue specimens, a
10 mm layer was removed from each side of the plate
by low speed milling. This was done to avoid contamination of the specimens from loose or broken inclusions, porosity, clusters etc due to hot rolling. The
dogbone specimens (Fig. 1) were milled to an aerospace standard of average surface roughness
Ra 0:8 lm with the crack plane surface being perpendicular to the rolling direction. All tests were carried
out using specimens oriented with the tension axis parallel to the rolling direction and the fatigue surface
perpendicular to the rolling plane (PRP).
2.2. The peening conditions
The CSP conditions were selected through an experimental database created during the course of this programme. The database [13] contains data of residual
stress proles, work-hardening proles and surface
roughness measurements from a selection of shot
media, coverage and intensity combinations. Two
dierent approaches for the selection of the peening
conditions were used, the Design of Experiments
(DoE)/Robust Design Methodology and the Eects
Neutralisation Model (ENM).
The DoE is an experimental approach to studying
the interaction eects between two or more factors in
an experimental programme known as factorial design
[1316]. In brief, the steps and order characterising the
DoE are: a) designation of critical factors aecting a
Table 2
Mechanical and physical properties of 2024-T351 at room temperature [10,11]
Elastic modulus (GPa)
Shear modulus (GPa)
Poissons ratio
Mon. yield stress (MPa)
Cyclic yield stress (MPa)
7274
2728
0.33
325340
420450
Hardness (HB)
Fr. toughness (MPam1/2)
Ult. tensile strength (MPa)
Endurance limit (R=1)
Shear strength (MPa)
115120
3134
490520
135140
285301
851
meter Zi,
rnom
1 1
r
Zi
where
2
31 =2
p
a
i 6b
7
Zi
4 q 5
a b ki
2
1k
i
iD
a2 b 2
The parameter i represents the number of half grains
which constitute the fatigue damage (crack and crack
are dimensionless forms
tip plastic zone). a and b
of the notch depth and half width respectively, i.e.
2b=D, and D is the average grain
a 2a=D and b
size. Using Eq. (3) and the NavarroRios model for
microstructural crack growth [20], Curtis et al. [17]
proposed that the necessary closure stress (representing
the eect of the residual stress prole on the crack
wake) able to fully neutralised the eect of surface
852
1 a
r1
f Residual stress da
6
a 0
Each approach concluded into dierent optimum peening conditions. The DoE suggested: a steel shot desigv
nated as S110 ( 0.279 mm), angle of impact of 45
and a coverage rate of 200%. The ENM concluded that
the optimum conditions are: S110, angle of impact of
v
90 and a coverage rate of 100%. Prior to peening, the
peening machine was calibrated in terms of ow rate
for the selected shot. The input parameters were: pressure 345 MPa, nozzle stand-o distance 152.4 mm, ow
rate 4.54 Kgr/min and Vernier value 60%. According
to the calibration, the 100% coverage requires two
passes of the nozzle while the 200% requires four
passes. Figs. 3 and 4 show the residual stress and
microhardenss prole of the selected peening parameters. Residual stress measurements were performed
Fig. 3. Distribution of residual stress versus depth for the two optimum CSP conditions. The residual stress of the as-machined material
is also depicted for comparison.
CSP Condition
Ra (lm)
Rtm (lm)
Sm (mm)
Kt
DoE
ENM
4.307
4.507
25.017
30.074
0.129
0.156
1.407
1.404
Fig. 5.
853
Roughness proles taken from identical roughness proling conditions for a) as-machined and b) peened coupons (S110/45 /200%).
Fig. 6. S-N response of the as-machined and the two selected peening conditions. The arrows indicate run-outs.
854
Fig. 8. Crack growth rates for the as-received, DoE and ENM
conditions. The peak stress was 270 MPa.
techniques the above could be considered as engineering sound. In addition, examination of the crack length
distribution versus the corresponding number of cycles
reveals that the propagation of the DoE and ENM is
slightly slower to that of the as-machined specimens.
The above can be representative of the crack closure
eect provided by the residual stresses on crack propagation (see Fig. 8). The propagation rates for the DoE
and ENM appear to follow the residual stress prole
exhibit as a result of the residual stress prole with
their peak to be found around the 200 lm depth.
3. Analysis of fatigue data and discussion
From the previous analysis it is clear that the eect
of CSP on the fatigue behaviour of the 2024-T351 can
be attributed to a prolonged period of crack arrest as
well as slower growth rates. Thus, in order to incorporate the residual stress prole to damage tolerant design
a distinction between crack propagation and arrest is
needed.
855
Fig. 12. Life improvement due to crack arrest (NI) normalised over
the total life (NT) for ENM peening conditions.
50% of the total life (~615 K cycles). It is also important to note that at 75% of life, the crack arrest
capacity drops below that of the as-machined material.
The above manifests that the residual closure stress
prole is lesser than that needed to counterbalance the
eect of the surface roughness. Such behaviour can
explain the fact that the improvement caused by the
CSP on the endurance limit (in this work set at 7 M
cycles) of the material is not representative to the
residual stresses and therefore the current practice of
using the residual stress prole as a far-eld stress
modulator can lead to erroneous results. In addition,
the use of CSP to improve the fatigue limit of the
material (set at >10 M cycles) is questionable since the
relaxation of the residual stress prole shows a nonsaturation behaviour.
Using the methodology depicted in Fig. 11, predictions can be performed regarding the classication of
the life improvement to that due to the crack arrest
and crack propagation. Such a prediction is shown in
Fig. 12.
Fig. 12 indicates that the life improvement due to
crack arrest decreases with the applied stress. The
behaviour is representative of the eect of the applied
stress to control the residual stress relaxation prole.
4. Conclusions
From this work the following conclusions can be
drawn for the fatigue response of the 2024-T351 to
CSP:
856
. The relaxation of the residual stress prole is of primary importance and should be included into damage tolerance methodologies.
. The relaxation of the residual stresses seems to
depend on the applied stress while the basic residual
stress prole remains unaected.
. Severe residual stress relaxation can cause the degradation of the fatigue performance of the material.
. The use of the residual stresses as far-eld stress
modulator according to the popular Dre
(maximumresidual stress) should be avoided since it
will overestimate the true eect of the residual stress.
. The use of CSP to improve the endurance limit
should be accompanied by extensive and thorough
analysis of the dynamics of the residual stress prole.
Acknowledgements
The authors gratefully acknowledge the nancial support from Airbus UK, the EPSRC, the Royal Academy
of Engineering and ConacyT. Special merit should also
be given to Mr. J. W. Eichler and Mr. J. M. Ordieres for
performing some of the experimental work as well as to
Mr. J. Goodllife for his technical support.
References
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[3] Martin U, Altenberger I, Scholtes B, Kremmer K, Oettel H.
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6980.
[4] Romero Solis J, de los Rios ER, Fam HY, Levers A. Optimisation of the shot peening process in terms of fatigue resistance.
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