scholarly journals Effect of Cavitation Peening on Fatigue Properties in Friction Stir Welded Aluminum Alloy AA5754

Metals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 59
Author(s):  
Hitoshi Soyama ◽  
Michela Simoncini ◽  
Marcello Cabibbo
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Fatigue Life ◽  
Compressive Residual Stress ◽  
Diffraction Method ◽  
Fatigue Properties ◽  
Surface Residual Stress ◽  
Friction Stir ◽  
Sheet Cavitation ◽  
Lightweight Metals

Friction stir welding (FSW) is an attractive solid-state joining technique for lightweight metals; however, fatigue properties of FSWed metals are lower than those of bulk metals. A novel mechanical surface treatment using cavitation impact, i.e., cavitation peening, can improve fatigue life and strength by introducing compressive residual stress into the FSWed part. To demonstrate the enhancement of fatigue properties of FSWed metal sheet by cavitation peening, aluminum alloy AA5754 sheet jointed by FSW was treated by cavitation peening using cavitating jet in air and water and tested by a plane bending fatigue test. The surface residual stress of the FSWed part was also evaluated by an X-ray diffraction method. It was concluded that the fatigue life and strength of FSWed specimen were improved by cavitation peening. Whereas the fatigue life at σa = 150 MPa of FSWed specimen was about 1/20 of the bulk sheet, cavitation peening was able to extend the fatigue life of the non-peened FSW specimen by 3.6 times by introducing compressive residual stress into the FSWed part. This is the first paper to demonstrate the improvement of fatigue properties of FSWed metallic sheet by cavitation peening.

Improvement of Fatigue Properties in a Cast Aluminum Alloy by Roller Burnishing and Friction Stir Processing

2014 ◽  
Vol 891-892 ◽  
pp. 662-667 ◽  
Author(s):  
Yuki Nakamura ◽  
Masaki Nakajima ◽  
Hiroaki Masuda ◽  
Toshifumi Kakiuchi ◽  
Yoshihiko Uematsu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Compressive Residual Stress ◽  
Fatigue Tests ◽  
Fatigue Properties ◽  
Cast Aluminum Alloy ◽  
Cast Aluminum ◽  
Bending Fatigue ◽  
Friction Stir

Roller burnishing (RB) and friction stir processing (FSP) were applied to a cast aluminum alloy, AC4CH-T6 (equivalent to A356-T6), to improve the fatigue properties. In roller burnished specimens, Vickers hardness was increased until the depth of 60μm compared with that of the as-cast specimens, resulting in work-hardening by RB. The compressive residual stress on the surface of the roller burnished specimens was also increased from 35MPa to 132MPa. In order to investigate the effect of RB on the fatigue properties, rotary bending fatigue tests have been performed using the roller burnished and the as-cast specimens. The roller burnished specimens exhibited higher fatigue strength than the untreated specimens. It is due to the increase in hardness and compressive residual stress by RB. In addition, plane bending fatigue tests have been performed using the friction stir processed and untreated specimens. Fatigue strengths of the friction stir processed specimens were highly improved compared with untreated specimens as the results of the elimination of casting defects by FSP. However, the crack growth rates of the friction stir processed specimens were faster than those of untreated specimens. It is due to the softening of the material by heat input during the FSP.

Residual Stress Evaluation Induced by Fatigue Crack in Shot Peened, Notched Specimens

2017 ◽  
Vol 885 ◽  
pp. 280-285
Author(s):  
Dávid Cseh ◽  
Valéria Mertinger ◽  
János Lukács
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
Stress Relaxation ◽  
Compressive Residual Stress ◽  
Diffraction Method ◽  
Fatigue Properties ◽  
Operational Parameters ◽  
Surface Residual Stress ◽  
Residual Stress State ◽  
Residual Stress Relaxation

The advantages of applied compressive residual stress on fatigue properties of materials is a well-described topic, but the residual stress state of machine elements can change during application, therefore it is necessary to describe how these changes are related to the operational parameters. So the monitoring of residual stress relaxation gives more details to improve the lifetime. The surface residual stress state evolution of hardened (quenched and tempered), shot peened, 2 side notched quadratic fatigue specimens made of 42CrMO4 steel was investigated nondestructively by X-ray diffraction method. Residual stress state was monitored on the surface with 1 mm spatial resolution in 5 mm environment of the notch. The compressive residual stress relaxation associated the notching and the fatigue test and the reversal of sign of the residual stress (from compression to tension) associated the crack propagation were experimentally showed.

Effect of Milling Speed and Feed on Surface Residual Stress of 7050-T7451 Aluminum Alloy

2012 ◽  
Vol 499 ◽  
pp. 217-222 ◽  
Author(s):  
C. Li ◽  
Yi Wan ◽  
R.R. Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Speed ◽  
Diffraction Method ◽  
Cutting Condition ◽  
Feed Speed ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Orthogonal Direction ◽  
Machined Surface

The residual stress in the milling of 7050-T7451 aluminum alloy was measured using X-ray diffraction method in which Psi-oscillation, Phi-oscillation and peak fit were adopted. Cutting speed and feed are main variables which were considered in this study. The results show that compressive residual stresses are generated in surface for the down milling generally, which is mainly due to burnishing effect between the tools flank face and the machined surface. In feed and its orthogonal direction, the effect of cutting speed and feed speed on residual stress is similar. Therefore, required residual stress can be achieved by controlling the cutting condition such as cutting speed, feed speed etc.

scholarly journals Fatigue Life Improvement of the High Strength Steel Welded Joints by Ultrasonic Impact Peening

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 619 ◽  
Author(s):  
Ján Lago ◽  
Libor Trško ◽  
Michal Jambor ◽  
František Nový ◽  
Otakar Bokůvka ◽  
...  
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Welded Joints ◽  
Compressive Residual Stress ◽  
High Strength ◽  
Fatigue Properties ◽  
Low Alloy Steel ◽  
Residual Stress Field ◽  
Near Surface ◽  
Life Improvement

Ultrasonic impact peening was applied on welded joints manufactured from Strenx 700 MC high strength low alloy steel with the aim to improve the fatigue properties. Three different surface treatment parameters were tested, which resulted in transformation of the near-surface tensile residual stresses in the weld metal and heat affected zone to compressive residual stress field, while maximal values from −400 MPa up to −800 MPa were reached. The highest fatigue life improvement was reached by the double peening with the 85 N contact force, where the fatigue limit for N = 108 cycles increased from 370 MPa to 410 MPa.

Fatigue Life Variance Prediction Incorporating Residual Stress Scatter Induced by Super-Finishing Grinding Process

2009 ◽  
Vol 416 ◽  
pp. 45-50
Author(s):  
Guang Hui Lu ◽  
Xue Ping Zhang ◽  
Er Wei Gao
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Diffraction Method ◽  
Machining Process ◽  
Stress Distributions ◽  
X Ray Diffraction ◽  
Machining Processes ◽  
Surface Residual Stress ◽  
Bearing Rings ◽  
The Impact

It is well known that there is a lager deviation in the fatigue life of machined components even under nominally identical loading conditions. Understanding and controlling fatigue life variance are essential to enhance reliability. However, few research focus on the impact of machining processes on the fatigue life variance of machined components. In this study, surface residual stress distributions of bearing rings randomly selected from a production line by super-finishing grinding, are measured by X-ray diffraction method in cutting and feed direction, and its scatter is analyzed by statistical tools. Based on the variance prediction theories, build a simplified fatigue life variance prediction model incorporating the resultant residual stresses scatter induced by machining process. Based on the Basquin equation, the model is validated by experimental data published in literature. The predicted fatigue life agrees well with the experimental average fatigue life. Statistical analysis shows that the predicted variances of fatigue life are equal to those estimated from experimental fatigue life.

scholarly journals Sequential Effects of Deep Rolling and Post-Weld Heat Treatment on Surface Integrity of AA7075-T651 Aluminum Alloy Friction Stir Welding

Materials ◽  
2019 ◽  
Vol 12 (21) ◽  
pp. 3510 ◽  
Author(s):  
Adirek Baisukhan ◽  
Wasawat Nakkiew
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Aluminum Alloy ◽  
Fatigue Life ◽  
Friction Stir Welding ◽  
Surface Integrity ◽  
Post Weld Heat Treatment ◽  
Deep Rolling ◽  
Friction Stir ◽  
Weld Heat

The aim of this research is to investigate the sequence of processes for improving the welded surface integrity of AA7075-T651 aluminum alloy joined by friction stir welding (FSW). The improvement processes that will be investigated herein include mechanical surface improvement with deep rolling (DR) and post-weld heat treatment (PWHT). Therefore, this study investigated welded surface integrity, which comprises residual stress, microhardness, surface roughness, microstructure, and fatigue life (screening). The experiment consists of three sets of combinations. In the first set, only FSW was applied; in the second set, FSW was applied, followed by DR, and then PWHT processes (FSW-DR-PWHT); and in the last set, FSW was applied, followed by PWHT, and then DR processes (FSW-PWHT-DR). Fatigue testing was carried out by undertaking a four-point bending test using a bending stress of approximately 300 MPa with a test frequency of 2.5 Hz at room temperature and stress ratio R = 0. The study found that residual stress plays an important role in the fatigue life. Finally, the fatigue test showed that FSW workpieces subject to the PWHT process followed by the DR process (FSW-PWHT-DR) had the highest fatigue life, with an increase of 239% when compared with unprocessed FSW workpieces.

Influence of Deep Rolling Process Parameters on Surface Residual Stress of AA7075-T651 Aluminum Alloy Friction Stir Welded Joint

2018 ◽  
Vol 939 ◽  
pp. 23-30 ◽  
Author(s):  
Adirek Baisukhan ◽  
Wasawat Nakkiew
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Residual Stresses ◽  
Compressive Residual Stress ◽  
Welded Joint ◽  
Rolling Process ◽  
Rolling Speed ◽  
Deep Rolling ◽  
Friction Stir ◽  
Rolling Pressure

Friction stir welding is most commonly used for joining aluminum alloy parts. After welding, residual stresses occurred in the welded joint caused by non-uniform cooling rate. Friction stir welding usually generates tensile residual stress inside the workpiece which affects the strength in addition to the fatigue life of materials. Compressive residual stress usually is beneficial and it can be introduced by mechanical surface treatment methods such as deep rolling, shot peening, laser shock peening, etc. In this research, deep rolling was used for inducing compressive residual stress on surface of friction stir welded joint. The residual stresses values were obtained from X-ray diffraction machine. Influence of three deep rolling process parameters: rolling pressure, rolling speed and rolling offset on surface residual stresses at the welded joint were investigated. Each factor had 2 levels (23 full factorial design). The statistical analysis result showed that the rolling pressure, rolling speed, rolling offset, interaction between rolling pressure and rolling speed, interaction between rolling speed and rolling offset were statistically significant factors, with the most compressive residual stress value approximately -391.6 MPa. The appropriated deep rolling process parameters on surface residual stress of AA7075-T651 aluminum alloy friction stir welded joint were 1) rolling pressure about 150 bar 2) rolling speed about 1,400 mm/min 3) rolling offset about 0.1 mm.

Microstructure and Fatigue Properties of Aero Aluminum Alloy Repaired by Laser Melt Casting

2011 ◽  
Vol 314-316 ◽  
pp. 1871-1875 ◽  
Author(s):  
Chang Liang Lu ◽  
Fang You Hu ◽  
Xu Ren Huang ◽  
De Xian Yi ◽  
Ai Yong Cui ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Fatigue Life ◽  
Composite Powder ◽  
Crystal Size ◽  
Axial Direction ◽  
Fatigue Properties ◽  
Crystallographic Axis ◽  
Al Matrix Composite ◽  
Al Matrix

The paper presents a study of renovation of aerial aluminum alloy (LY12CZ) by laser melt casting with Al matrix composite powder. The microstructure of the melt casting zone was investigated, and the fatigue contrast test was carried out between the repaired specimens and the undamaged specimens. It is found that the melt casting zone consists of equiaxed crystals and columnar crystals. The equiaxed crystals distribute in the deposited layer and the crystal size is about 3~4μm. The columnar crystals whose axial direction size comes to 30μm~40μm exist near the interface with its crystallographic axis perpendicular to the interface. The fatigue life of specimens repaired by laser melt casting was shorter than no-damage specimens to a large extant, because of the flaws in the deposited layer engendered the origins of cracks; the columnar shape grains at the bottom of casting zone were easy to split under the tensile stress; the residual stress after the melt casting accelerated the initiation and growth of the cracks.

Numerical Study on Strengthening Effect of Laser Shot Peening for Wrought Magnesium Alloy

2012 ◽  
Vol 217-219 ◽  
pp. 2234-2237 ◽  
Author(s):  
Su Qin Jiang ◽  
Hong Guang Xu
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Shot Peening ◽  
Compressive Residual Stress ◽  
Numerical Study ◽  
Back Analysis ◽  
Laser Shot ◽  
Fatigue Properties ◽  
Strengthening Effect ◽  
Fea Model

Based on finite element method, the FEA model used for analyzing fatigue properties of sample treated by laser shot peening (LSP) was established. In order to research the influence of material intensity on LSP effect, two kinds of wrought magnesium alloys AZ31B and ZK60 with different intensity were chosen as object, the compressive residual stress and fatigue life after LSP were analyzed. After spring back analysis the elastic strain is released in material inner, the value of compressive residual stress was reduced; after LSP with 3 times, the fatigue life gains of AZ31B and ZK60 were 105% and 163%, respectively. The results show that strengthening effect of high intensity material treated by LSP is better than that of low intensity material.

Comparison of Fatigue Behavior of FS (Friction Stir) and TIG Welded Al 6N01 Alloy

2009 ◽  
Vol 417-418 ◽  
pp. 593-596
Author(s):  
K.H. Yoon ◽  
S.I. Kwun ◽  
Yun Mo Yeon
Keyword(s):  
Residual Stress ◽  
Growth Rate ◽  
Fatigue Crack ◽  
Compressive Residual Stress ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Cyclic Hardening ◽  
Fatigue Properties ◽  
Cycle Fatigue ◽  
Friction Stir

The fatigue properties of friction stir (FS) and TIG welded Al 6N01-T5 alloys were compared in the present study. The low cycle fatigue (LCF) test was performed under total strain amplitudes in the range of ± 0.6 ~ ± 1.5% and with a strain rate of 3 x 10-3/s. During low cycle fatigue, the base metal showed little cyclic hardening or softening, whereas both the FS and TIG welded zones showed a large amount of cyclic hardening until fracture, although the fatigue life of the TIG welded zone was much shorter than that of the FS welded zone. The fatigue crack growth rate (FCGR) was retarded in the heat affected zone (HAZ) on the advancing side of the FS welded zone, due to the compressive residual stress in this region. The differences in the fatigue properties in these two welded zones were discussed in terms of the microstructural changes during fatigue.

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