Materials Science Forum Vols. 768-769

Abstract: Test samples of grey and compacted graphite cast irons with pearlitic matrix were shot-peened to different surface conditions using twelve different combinations of shot size, peening intensity and peening coverage percentage. Relatively high surface compressive residual stresses varying between 245 to 565 MPa were observed and the compressive residual stresses reached a depth between 280 µm and 770 µm. Within the range of peening parameters used, the compacted graphite cast iron with its vermicular graphite showed a somewhat better response to the same shot-peening treatment than the grey cast iron containing flake graphite, giving a larger peening affected zone with higher compressive residual stresses. For both the cast irons, an increase in peening coverage percentage, shot size or peening intensity led often to a lower surface compressive stress. However, peening using a higher intensity greatly increased the degree and extent of plastic deformation and therefore increased the magnitude and penetration depth of the subsurface compressive residual stresses, while the effect of increasing shot size also depends on the peening intensity. On the other hand, measurements on the grey cast iron samples showed that the peening coverage has little effect on the depth profile of residual stress.

Abstract: The different shot peening responds of a grey cast iron (GI) with its flake graphite and a compacted cast iron (CGI) with its vermicular graphite was analyzed and compared in this paper. For peening using identical parameters, CGI showed a larger plastic deformation zone with higher subsurface compressive stresses than GI. Electron backscatter diffraction (EBSD) mapping and backscatter electron imaging revealed that plastic deformation of the matrix near graphite inclusions is affected by the size and geometry of the graphite. The different behaviors of graphite are explained by their capability to damp mechanical force but at the same time to cause stress concentration in the matrix. The better shot peening results for CGI may be attributed to a lower damping effect of its graphite inclusions and capability of the matrix for larger plastic deformation.

Abstract: Shot peening is an important surface treatment which can induce compressive residual stress and refine micro-structure in the deformed surface layer. In this paper, the conventional shot peening, dual shot peening and triple shot peening have been applied to S30432 austenitic stainless steel. The residual stress and micro-structure in the deformed layer were investigated by X-ray diffraction method. The results revealed that a compressive residual stress field was induced in the deformed layer for all shot peening conditions. As the shot peening step increased, the compressive residual stresses increased in near surface layer, and then deceased faster in deeper deformed layer. In terms of microstructure, the domain size increased, while the micro-strain decreased with the depth increasing in the deformed layer. Compare with the effect of three different shot peening method, triple shot peenng is more effective to optimize the compressive residual stress, microstructure and micro-hardness of S30432 austenitic stainless steel.

Abstract: The thermal relaxation behavior of residual stress and microstructure at high temperatures in S30432 austenitic stainless steel after shot peening was investigated by X-ray residual stress analyzer. The effects of exposure time and applied temperature on the residual stress and microstructure relaxation were particularly analyzed and discussed. A significant decrease of the residual stress values were observed in the first period of exposure time, followed by slowing down and then stabilization. It was also observed that a higher applied temperature produced greater relaxation. In terms of microstructure, the domain size and micro-strain were calculated by Voigt method, the results showed that the refined domain size and high micro-strain induced by shot peening were greatly relaxed at the first stage of annealing, then stabilized. With higher annealing temperature, the recrystallization behavior in the shot peened deformed layer was more obvious. Based on the results of line profile analysis, the recrystallization activation energy and micro-strain relaxation energy were calculated, respectively.

Abstract: The specimen material was austenitic stainless steel, SUS316L. The residual stress was induced by water-jet peening. The residual stress was measured using the 311 diffraction with conventional X-rays. The measured residual stress showed the equi-biaxial stress state. To investigate thermal stability of the residual stress, the specimen was aged thermally at 773 K in air to 1000 h. The residual stress kept the equi-biaxial stress state against the thermal aging. Lattice plane dependency of the residual stress induced by water-jet peening was evaluated using hard synchrotron X-rays. The residual stress measured by the soft lattice plane showed the equi-biaxial stress state, but the residual stress measured by the hard lattice plane did not. In addition, the distributions of the residual stress in the depth direction were measured using a strain scanning method with hard synchrotron X-rays and neutrons.

Abstract: The consequences of near surface materials properties and residual stress states produced by specific manufacturing operations on damage evolution during corrosion fatigue of the Al-base alloys AA359.0 (German grade G-AlSi9Cu3) and AA6060 (German grade AlMgSi0.5) were systematically investigated. Specimens were processed applying mechanical surface treatments like shot peening or deep rolling and investigated in comparison with turned states. Surface topographies as well as near surface work hardening states and residual stress depth distributions were analyzed. Tension-compression fatigue tests were carried out under laboratory air as well as under salt spray test conditions or in salt solution. Crack formation and crack propagation was studied and characteristic examples are presented. The influence of the mechanical surface treatments on the electrochemical behavior was also investigated. To assess the consequences of near surface materials properties on the corrosion fatigue behavior, their stability during fatigue, in particular the relaxation of residual stress distributions introduced by mechanical surface treatments, was taken into account.

Abstract: Generating compressive residual stress states with high gradients and low penetration depths offers high capability regarding increase of fatigue limit of parts. In this work the determination of such specific residual stress distributions by using X-ray diffraction and a little material removal is introduced. Measurements are compared using two interference peaks of different penetration depths, at which confocal microscopy enables high accuracy in determination of the step sizes in electrochemical machining. Furthermore the realisation of these states by two different peening processes using micro blasting media is described. The suitability of the processes micro peening and ultrasonic wet peening as surface treatment methods to improve fatigue limit are shown. Micro peening is based on the shot peening principle with small shots and ultrasonic wet peening on the acceleration of small blasting particles by cavitation. The investigations were conducted at AISI 4140 in a quenched and tempered state. Besides the residual stresses and the integral width of interference peaks as well as the depth distributions, the surface topography was examined. The beneficial effects of these conditions on the fatigue limit in bending tests are described.

Abstract: A detailed study of the complex triaxial residual stress distribution of the double-pass friction stir welded (FSW) lap-joint between two different high strength aluminum alloy sheet materials was conducted. A non-destructive technique known as neutron diffraction was used to measure the internal residual stress distribution in the three principal direction of the lap-joint in the as-welded and hammer peened configurations to determine effects of hammer peening on redistribution of residual stresses across the weld. The residual stress variation across the weld in the transverse direction contained the highest values of tensile stress in all three principal directions. The residual stress in the hammer peened test specimen was in most cases reduced in all three principal directions.

Abstract: A new method has been designed to automatically adapt the geometry of the fusion zone of a weld according to the temperature calculations when the thermal welding heat source parameters are known. In the material definition in a Finite Element code for welding stress calculations, the fusion zone material has different properties than the base material since, among others, the temperature at which the material is stress free is the melting temperature instead of room temperature. In this work, the fusion zone has been determined by postprocessing the thermal model results. The calculated dimensions of the fusion zone have been used as an input for a user subroutine which automatically creates a Finite Element mesh that separates fusion zone elements and base material elements according to the physical reality. It has been shown that the method allows a more accurate stress prediction in the fusion zone and the heat affected zone close to the fusion line, where residual stresses can be important. Neutron diffraction measurements have been used as a validation of the model.

Abstract: In spite of an increased awareness of welding residual stress threat to structural integrity, the extent of its influence on fatigue especially under multiaxial loading is still unclear and is a matter of debate. One important reason for this lack of clarities is that the determination of the initial welding residual stress field in welded structures even at the fatigue crack initiation sites is difficult and requires complementary instruments. Since the fatigue crack initiation in sound welds almost always occurs on the surface, the determination of surface residual stresses could increase the awareness of the extent of their threat to the structural safety. In this paper the development of residual stresses in different TIG-welded tubular specimens out of S355J2H and S690QL steel is studied and compared. The mechanisms of the development of residual stresses based on heat input and cooling rate are discussed. The welding parameters and thus heat inputs are varied and the mechanisms leading to different residual stress states are investigated. X-ray method was used for residual stress state characterization.