Advanced Surface Enhancement: Proceedings of the 1st International Conference on Advanced Surface Enhancement (INCASE 2019)—Research Towards Industrialisation [1st ed. 2020] 978-981-15-0053-4, 978-981-15-0054-1

Table of contents :
Front Matter ....Pages i-xii
Front Matter ....Pages 1-1
Optimization of Shot Peening for Titanium Alloys Ti 10-2-3 in CONDOR Project (Corentin Dides, Thomas Billot, Nicolas Guillemot)....Pages 3-9
Mechanical Investigations on Composite Peened Aluminium (Michael Seitz, Kay André Weidenmann)....Pages 10-18
Influence of Wetblast Treatment on Fatigue Strength of Magnesium Alloy AZ31 (Koichiro Nambu, Kenta Takashima, Isao Kumagai, Masahiro Okumiya)....Pages 19-25
Process Model for Evaluating the Peen Velocity in Shot Peening Machine (Nguyen Van Bo, Ba Te, Augustine Teo, Kunal Ahluwalia, Ampara Aramcharoen, Kang Chang Wei)....Pages 26-35
Experimental Study of Single Shot Process: Toward a Surface State Predictive Tool (Benjamin Levy, El Mansori Mohamed, Sabeur Mezghani, M. El Hadrouz, Julien Cabrero, Anne-Laure Beaudonnet)....Pages 36-45
Microstructural Changes in Electroplated Chromium Coating–Substrate Interfaces Induced by Shot Peening (Yutaka Kameyama, Tatsuya Ohta, Keita Sasaki, Hideaki Sato, Ryokichi Shimpo)....Pages 46-55
Investigation on Theoretical Analysis of Residual Stress Distribution Induced by Shot Peening in 2397 Aluminum-Lithium Alloy (Yukui Gao, Xuefei Tao)....Pages 56-68
Effect of Shakedown on the Fatigue Limit of Ultrasonic Shot Peened Steel (Jinta Arakawa, Yoshiichirou Hayashi, Hiroyuki Akebono, Atsushi Sugeta)....Pages 69-75
Fundamentals and Applications of Cavitation Peening Comparing with Shot Peening and Laser Peening (Hitoshi Soyama)....Pages 76-87
Effect of Mechanical Properties on Fatigue Life Enhancement of Additive Manufactured Titanium Alloy Treated by Various Peening Methods (Yuya Okura, Hirotoshi Sasaki, Hitoshi Soyama)....Pages 88-96
Influence of Burnishing Process on Microstructure and Corrosion Properties of Mg Alloy AZ31 (Chenyao Cao, Jiang Zhu, Tomohisa Tanaka)....Pages 97-107
Effects of Machine Hammer Peened Surface Textures on the Tribological Behavior of Stamping Tools (Peter Sticht, Johannes Hohmann, Peter Groche)....Pages 108-120
Mechanical Properties Enhancement of Additive Manufactured Ti-6Al-4V by Machine Hammer Peening (Leonor Neto, Stewart Williams, Jialuo Ding, Jan Hönnige, Filomeno Martina)....Pages 121-132
An Automated Deposition Procedure for Cold Spray Additive Manufacturing Process Modeling Based on Finite Element Simulation (Sabeur Msolli, Zhi-Qian Zhang, Junyan Guo, Sridhar Narayanaswamy, Reddy Chilla Damodara, Zheng Zhang et al.)....Pages 133-143
Bonding Strength Improvement Through Numerical Simulation of Particle Impact Process During Metal Cold Spray (X. Song, X. Z. Jin, J. Everaerts, W. Y. Tan, W. Sun, I. Marinescu et al.)....Pages 144-152
Front Matter ....Pages 153-153
Surface Texture Evaluation on Mirror Finish Surface Using Patterned Area Illumination Method (Shaowei Fu, Fang Cheng, Tegoeh Tjahjowidodo)....Pages 155-162
Sliding Behavior of Secondary Phase SiC Embedded Alloyed Layer Doped Ti6Al4V Surfaces Ensuing Electro Discharge Machining (Jibin T. Philip, Deepak Kumar, Jose Mathew, Basil Kuriachen)....Pages 163-172
Measurement of Residual Stresses on Deep Rolled Round Aluminum Samples Using Hole Drilling Strain Gage Method (Mehmet Okan Görtan, Berkay Yüksel, Bilsay Sümer)....Pages 173-181
Mechanical Stress Relaxation of a Laser Peened and Shot Peened Ni-Based Superalloy (Kai Siang Chin, Sridhar Idapalapati, Anna Paradowska, Mark Reid, Shashwat Shukla, Dennise Tanoko Ardi)....Pages 182-189
Incorporation of Evaluation Technology into Shot Peening Equipment (Kan Aoki, Yuji Kobayashi, Yoshiyasu Makino)....Pages 190-197
Influence of the Feed Rate in the Single-Lip Deep Hole Drilling Process on the Surface Integrity of Steel Components (Jan Nickel, Nikolas Baak, Frank Walther, Dirk Biermann)....Pages 198-212
Front Matter ....Pages 213-213
Improvement of Chipping Phenomena for Crustaceous Materials Rounding by Centrifugal Barrel Finishing (Hiroki Mizuno, Hiroaki Suesuga)....Pages 215-225
In Situ Measurement of Granular Pressure and Velocity on Component Surfaces in Stream Finishing (Sho Itoh, Jeremy Ho, Cary Turangan, Stephen Wan)....Pages 226-233
Development of Rheology and Computational Flow Model for Robotized External Finishing on Additively Manufactured Components (Cary Kenny Turangan, Stephen Wan Yee Ming, Sho Itoh, Jeremy Ho)....Pages 234-243
Effects of Combined Wear Mechanisms in Internal Surface Finishing Using Controlled Hydrodynamic Cavitation Abrasive Finishing Process (Arun Prasanth Nagalingam, Swee Hock Yeo)....Pages 244-253
Surface Integrity Characteristics of NiTiHf High Temperature Shape Memory Alloys (Yusuf Kaynak, Emre Tascioglu, Othmane Benafan)....Pages 254-262
The Effect of Finish-Milling Operation on Surface Quality and Wear Resistance of Inconel 625 Produced by Selective Laser Melting Additive Manufacturing (Emre Tascioglu, Yusuf Kaynak, Özgur Poyraz, Akın Orhangül, Soner Ören)....Pages 263-272
Toolpath Generation for Robot Filleting (Srinivasan Lakshminarayanan, Omey Mohan Manyar, Domenico Campolo)....Pages 273-280
Front Matter ....Pages 281-281
Effect of Bubble Radius on Ability of Submerged Laser Peening (Hirotoshi Sasaki, Yuka Iga, Hitoshi Soyama)....Pages 283-291
Crack Retardation of Damage Through Enhanced Crack Closure Effect Induced by Laser Peening (Yongxiang Hu, Han Cheng)....Pages 292-297
Application of Laser Peening for Cold Work Steel (Norihito Shibuya, Fumiaki Kumeno, Yuki Nakamura, Ryo Yoshinouchi)....Pages 298-304
Influence of Laser Shock Peening (LSP) on the Material Properties of Additive Manufactured IN718 (Ching Kiat Yong, Geoff D. West, Greg J. Gibbons, Chow Cher Wong)....Pages 305-313
A Comparison of Surface and Sub-surface Features Induced by Shot Peening vs. Laser Peening on a Duplex Aged Beta Ti Alloy (S. Sudhagara Rajan, Geetha Manivasagam, Sathya Swaroop, Nageswara Rao Muktinutalapati)....Pages 314-320
Effect of Laser-Induced Microstructure in Cavitation Erosion Performance of Martensitic Stainless Steel (Niroj Maharjan, Dennise Tanoko Ardi)....Pages 321-329
Effect of In-Situ Laser Remelting on the Microstructure of SS316L Fabricated by Micro Selective Laser Melting (Balasubramanian Nagarajan, Zhiheng Hu, Shubo Gao, Xu Song, Rui Huang, Matteo Seita et al.)....Pages 330-336
Tailoring Surface Roughness of Micro Selective Laser Melted SS316L by In-Situ Laser Remelting (Zhiheng Hu, Balasubramanian Nagarajan, Xu Song, Rui Huang, Wei Zhai, Jun Wei)....Pages 337-343
Surface Structuring of Multilayer Coated Cutting Tool Using Nd: YVO4 Nanosecond Laser (Ahmed Alghamdi, Paul Mativenga)....Pages 344-357
Back Matter ....Pages 359-360

Citation preview

Lecture Notes in Mechanical Engineering

Sho Itoh Shashwat Shukla Editors

Advanced Surface Enhancement Proceedings of the 1st International Conference on Advanced Surface Enhancement (INCASE 2019)— Research Towards Industrialisation

Lecture Notes in Mechanical Engineering

Lecture Notes in Mechanical Engineering (LNME) publishes the latest developments in Mechanical Engineering - quickly, informally and with high quality. Original research reported in proceedings and post-proceedings represents the core of LNME. Volumes published in LNME embrace all aspects, subfields and new challenges of mechanical engineering. Topics in the series include: • • • • • • • • • • • • • • • • •

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Sho Itoh Shashwat Shukla •

Editors

Advanced Surface Enhancement Proceedings of the 1st International Conference on Advanced Surface Enhancement (INCASE 2019)—Research Towards Industrialisation

123

Editors Sho Itoh Advanced Remanufacturing and Technology Centre (ARTC) A*STAR Singapore, Singapore

Shashwat Shukla Advanced Remanufacturing and Technology Centre (ARTC) A*STAR Singapore, Singapore

ISSN 2195-4356 ISSN 2195-4364 (electronic) Lecture Notes in Mechanical Engineering ISBN 978-981-15-0053-4 ISBN 978-981-15-0054-1 (eBook) https://doi.org/10.1007/978-981-15-0054-1 © Springer Nature Singapore Pte Ltd. 2020 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, expressed or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore

Preface

Surface enhancement attracts a varied set of professionals with diverse backgrounds. It involves, for example, design engineers whose primary concern is functional safety and service life of the component. In development, it involves production engineers who aim to optimise process parameters to achieve high product quality. Further up the value chain, it attracts physicists and materials scientists, who explore fundamental aspects of surface modification to develop more advanced processes. This book contains a compilation of 37 papers presented in the first International Conference on Advanced Surface Enhancement (INCASE) held in Singapore during 10–12 September 2019, which brings the experts from all these different disciplines under one umbrella and establishes a dialogue amongst the wider surface enhancement community. This confluence of academia and industry not only brings forth innovative ideas to address the challenges that the industry faces today but inspires future inventions as well. Although the history of surface enhancement goes back several decades, it has seen rapid advances in the recent past. Practitioners and researchers belonging to different areas of this field will find these exciting developments comprehensively covered in this book. For physicists, it presents the state of the art in sensor development and integration of sensing devices with processing equipment to achieve more adaptive process control. For production engineers, it explores whether these developments can be harnessed for practical implementation to streamline their shop floor operations and make them more robust and effective. Similarly, materials scientists will find it stimulating that the current paradigm where confirmation of process integrity is deemed to assure part quality is being challenged, and attempts to enable in-line and in-process microstructure analysis of surface-enhanced component are gaining momentum. This is a critical area of development where a strong collaboration between academic researchers and practising engineers can help to solve some long-standing problems. With more robust measurement methods in place, in future, we can not only expect improvement in quality but also gather critical data on materials properties that can help in realising closed-loop control of surface enhancement processes. This area v

vi

Preface

will also attract the interest of readers from modelling and simulation community who are working on developing predictive capabilities for materials processing. Finally, as manufacturing moves towards higher automation and Industrie 4.0, questions are being asked on whether the surface enhancement community is prepared for this transformation. Considering the complexity of the process and the associated costs, will integrating sophisticated sensors, measurement devices, and IT infrastructure with processing equipment be practical on a large scale? Given the rapid pace at which manufacturing is changing, these questions are no longer exploratory and need to be included in strategic road maps. Focus on Industrie 4.0 being a unique feature of INCASE 2019, this book comprehensively addresses these questions by exploring potential technology gaps and the weaknesses and strengths of various alternative scenarios. We firmly believe that this book will excite both new practitioners and experienced professionals alike. Given the comprehensive scope of this book, readers will gain a much broader perspective of how the field of surface enhancement is evolving, so that the community is better prepared to capture future opportunities and overcome near-term as well as long-term challenges that lie ahead of us. June 2019

Sho Itoh Shashwat Shukla

Organisation

Conference Chair Alexander Korsunsky

University of Oxford, UK

Organising Chair Dennise Tanoko Ardi

Advanced Remanufacturing and Technology Centre, Singapore

Organising Committees Alexander Korsunsky Dennise Tanoko Ardi Steven Baiker Michael Yap Sho Itoh Shashwat Shukla Ampara Aramcharoen Chun Wai Kum Shi Ying Chan

University of Oxford, UK Advanced Remanufacturing and Technology Singapore Metal Finishing News, Switzerland Coventry University, UK Advanced Remanufacturing and Technology Singapore Advanced Remanufacturing and Technology Singapore Advanced Remanufacturing and Technology Singapore Advanced Remanufacturing and Technology Singapore Advanced Remanufacturing and Technology Singapore

Centre,

Centre, Centre, Centre, Centre, Centre,

vii

viii

Organisation

Technical Committees Alexander Korsunsky Michael Fitzpatrick Hitoshi Soyama Mario Guagliano Chuan Hai Jiang Lothar Wagner David Butler Hitoshi Omori Hirofumi Hidai Minghui Hong John Hock Lye Pang King Ho Holden Li Seung Ki Moon Tegoeh Tjahjowidodo Shikun Zou Xu Song Chang Wei Kang Jacek Kaminski Karsten Röttger Peter Beckmerhagen Yuji Kobayashi Michael Chen Janne Suoknuuti Hali Diep Domenico Furfari Thomas Haubold Wolfgang Hennig Waled Hassan Takashi Sato

University of Oxford, UK Coventry University, UK Tohoku University, Japan Politecnico di Milano, Italy Shanghai Jiao Tong University, China Technische Universität Clausthal, Germany University of Strathclyde, UK Institute of Physical and Chemical Research, Japan Chiba University, Japan National University of Singapore, Singapore Nanyang Technological University, Singapore Nanyang Technological University, Singapore Nanyang Technological University, Singapore Nanyang Technological University, Singapore AVIC Beijing Aeronautical Manufacturing Technology Research Institute, China Singapore Institute of Manufacturing Technology, Singapore Institute of High Performance Computing, Singapore Advanced Remanufacturing and Technology Centre, Singapore Ecoroll, Germany Frohn, Germany Sintokogio, Japan Kunshan Carthing Precision, China Stresstech, Finland Boeing, USA Airbus, Germany Rolls-Royce, Germany Rolls-Royce, Germany Rolls-Royce, Germany IHI Corporation, Japan

Contents

Fatigue Life Enhancement Optimization of Shot Peening for Titanium Alloys Ti 10-2-3 in CONDOR Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corentin Dides, Thomas Billot, and Nicolas Guillemot Mechanical Investigations on Composite Peened Aluminium . . . . . . . . . Michael Seitz and Kay André Weidenmann Influence of Wetblast Treatment on Fatigue Strength of Magnesium Alloy AZ31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Koichiro Nambu, Kenta Takashima, Isao Kumagai, and Masahiro Okumiya Process Model for Evaluating the Peen Velocity in Shot Peening Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nguyen Van Bo, Ba Te, Augustine Teo, Kunal Ahluwalia, Ampara Aramcharoen, and Kang Chang Wei Experimental Study of Single Shot Process: Toward a Surface State Predictive Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Benjamin Levy, El Mansori Mohamed, Sabeur Mezghani, M. El Hadrouz, Julien Cabrero, and Anne-Laure Beaudonnet Microstructural Changes in Electroplated Chromium Coating–Substrate Interfaces Induced by Shot Peening . . . . . . . . . . . . . Yutaka Kameyama, Tatsuya Ohta, Keita Sasaki, Hideaki Sato, and Ryokichi Shimpo Investigation on Theoretical Analysis of Residual Stress Distribution Induced by Shot Peening in 2397 Aluminum-Lithium Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yukui Gao and Xuefei Tao

3 10

19

26

36

46

56

ix

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Contents

Effect of Shakedown on the Fatigue Limit of Ultrasonic Shot Peened Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jinta Arakawa, Yoshiichirou Hayashi, Hiroyuki Akebono, and Atsushi Sugeta Fundamentals and Applications of Cavitation Peening Comparing with Shot Peening and Laser Peening . . . . . . . . . . . . . . . . . . . . . . . . . . Hitoshi Soyama Effect of Mechanical Properties on Fatigue Life Enhancement of Additive Manufactured Titanium Alloy Treated by Various Peening Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yuya Okura, Hirotoshi Sasaki, and Hitoshi Soyama Influence of Burnishing Process on Microstructure and Corrosion Properties of Mg Alloy AZ31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chenyao Cao, Jiang Zhu, and Tomohisa Tanaka

69

76

88

97

Effects of Machine Hammer Peened Surface Textures on the Tribological Behavior of Stamping Tools . . . . . . . . . . . . . . . . . . 108 Peter Sticht, Johannes Hohmann, and Peter Groche Mechanical Properties Enhancement of Additive Manufactured Ti-6Al-4V by Machine Hammer Peening . . . . . . . . . . . . . . . . . . . . . . . . 121 Leonor Neto, Stewart Williams, Jialuo Ding, Jan Hönnige, and Filomeno Martina An Automated Deposition Procedure for Cold Spray Additive Manufacturing Process Modeling Based on Finite Element Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Sabeur Msolli, Zhi-Qian Zhang, Junyan Guo, Sridhar Narayanaswamy, Reddy Chilla Damodara, Zheng Zhang, Jisheng Pan, Boon Hee Tan, and Qizhong Loi Bonding Strength Improvement Through Numerical Simulation of Particle Impact Process During Metal Cold Spray . . . . . . . . . . . . . . . 144 X. Song, X. Z. Jin, J. Everaerts, W. Y. Tan, W. Sun, I. Marinescu, W. Zhai, F. Li, E. J. Liu, and A. M. Korsunsky Product Verification and Material Characterisation Surface Texture Evaluation on Mirror Finish Surface Using Patterned Area Illumination Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Shaowei Fu, Fang Cheng, and Tegoeh Tjahjowidodo Sliding Behavior of Secondary Phase SiC Embedded Alloyed Layer Doped Ti6Al4V Surfaces Ensuing Electro Discharge Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Jibin T. Philip, Deepak Kumar, Jose Mathew, and Basil Kuriachen

Contents

xi

Measurement of Residual Stresses on Deep Rolled Round Aluminum Samples Using Hole Drilling Strain Gage Method . . . . . . . . 173 Mehmet Okan Görtan, Berkay Yüksel, and Bilsay Sümer Mechanical Stress Relaxation of a Laser Peened and Shot Peened Ni-Based Superalloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Kai Siang Chin, Sridhar Idapalapati, Anna Paradowska, Mark Reid, Shashwat Shukla, and Dennise Tanoko Ardi Incorporation of Evaluation Technology into Shot Peening Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Kan Aoki, Yuji Kobayashi, and Yoshiyasu Makino Influence of the Feed Rate in the Single-Lip Deep Hole Drilling Process on the Surface Integrity of Steel Components . . . . . . . . . . . . . . 198 Jan Nickel, Nikolas Baak, Frank Walther, and Dirk Biermann Surface Finishing and Machining Improvement of Chipping Phenomena for Crustaceous Materials Rounding by Centrifugal Barrel Finishing . . . . . . . . . . . . . . . . . . . . . . . 215 Hiroki Mizuno and Hiroaki Suesuga In Situ Measurement of Granular Pressure and Velocity on Component Surfaces in Stream Finishing . . . . . . . . . . . . . . . . . . . . . 226 Sho Itoh, Jeremy Ho, Cary Turangan, and Stephen Wan Development of Rheology and Computational Flow Model for Robotized External Finishing on Additively Manufactured Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Cary Kenny Turangan, Stephen Wan Yee Ming, Sho Itoh, and Jeremy Ho Effects of Combined Wear Mechanisms in Internal Surface Finishing Using Controlled Hydrodynamic Cavitation Abrasive Finishing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Arun Prasanth Nagalingam and Swee Hock Yeo Surface Integrity Characteristics of NiTiHf High Temperature Shape Memory Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Yusuf Kaynak, Emre Tascioglu, and Othmane Benafan The Effect of Finish-Milling Operation on Surface Quality and Wear Resistance of Inconel 625 Produced by Selective Laser Melting Additive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . 263 Emre Tascioglu, Yusuf Kaynak, Özgur Poyraz, Akın Orhangül, and Soner Ören

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Contents

Toolpath Generation for Robot Filleting . . . . . . . . . . . . . . . . . . . . . . . . 273 Srinivasan Lakshminarayanan, Omey Mohan Manyar, and Domenico Campolo Laser Processes Effect of Bubble Radius on Ability of Submerged Laser Peening . . . . . . 283 Hirotoshi Sasaki, Yuka Iga, and Hitoshi Soyama Crack Retardation of Damage Through Enhanced Crack Closure Effect Induced by Laser Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 Yongxiang Hu and Han Cheng Application of Laser Peening for Cold Work Steel . . . . . . . . . . . . . . . . 298 Norihito Shibuya, Fumiaki Kumeno, Yuki Nakamura, and Ryo Yoshinouchi Influence of Laser Shock Peening (LSP) on the Material Properties of Additive Manufactured IN718 . . . . . . . . . . . . . . . . . . . . . . 305 Ching Kiat Yong, Geoff D. West, Greg J. Gibbons, and Chow Cher Wong A Comparison of Surface and Sub-surface Features Induced by Shot Peening vs. Laser Peening on a Duplex Aged Beta Ti Alloy . . . 314 S. Sudhagara Rajan, Geetha Manivasagam, Sathya Swaroop, and Nageswara Rao Muktinutalapati Effect of Laser-Induced Microstructure in Cavitation Erosion Performance of Martensitic Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . 321 Niroj Maharjan and Dennise Tanoko Ardi Effect of In-Situ Laser Remelting on the Microstructure of SS316L Fabricated by Micro Selective Laser Melting . . . . . . . . . . . . 330 Balasubramanian Nagarajan, Zhiheng Hu, Shubo Gao, Xu Song, Rui Huang, Matteo Seita, and Jun Wei Tailoring Surface Roughness of Micro Selective Laser Melted SS316L by In-Situ Laser Remelting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Zhiheng Hu, Balasubramanian Nagarajan, Xu Song, Rui Huang, Wei Zhai, and Jun Wei Surface Structuring of Multilayer Coated Cutting Tool Using Nd: YVO4 Nanosecond Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Ahmed Alghamdi and Paul Mativenga Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Fatigue Life Enhancement

Optimization of Shot Peening for Titanium Alloys Ti 10-2-3 in CONDOR Project Corentin Dides1(&), Thomas Billot2, and Nicolas Guillemot3 1

IRT-M2P, 4 Rue Augustin Fresnel, 57000 Metz, France [email protected] 2 Safran Landing Systems, 9 Rue Guynemer, 64400 Bidos, France 3 Airbus Helicopters, Aéroport International Marseille-Provence, 13725 Marignane, France

Abstract. CONDOR is an R&D project lead by IRT-M2P with different industrial partnership to increase knowledge and simulation models of shot peening. This surface hardening process aims to perform different shots with high velocity on metallic surfaces to introduce compressive stresses on it. Fatigue behavior of shot peened parts is significantly improved. During this research project a DOE has been carried out to optimize shot peening parameters on titanium alloys (surface roughness before shot peening, size and shot’s hardness, covering and intensity). The DOE is composed by more than 300 fatigue specimens. All this data allows us to define specifically each shot peening parameter influence on shot penned parts efficiency. CONDOR project allows simulation development of models to simulate shot peening effect by taking into account the parameters introduced above. Those models are used to evaluate residual stress level and fatigue lifetime after shot peening and to confirm models readiness level. This study has defined optimized machining and shot peening conditions in order to increase parts fatigue lifetime. Keywords: Shot peening 4 point bending fatigue


Ti 10-2-3
Design of experiment


1 Introduction IRT M2P is a French institute of research and technology which is working on metallic materials and surfaces treatments. CONDOR project is a research and development project about shot peening. Different topics have been developed in this project; optimization of shot peening of Ti 10-2-3 alloys is one of them. Today, shot peening on titanium parts is similar to steel parts and it appears that shot peening in those conditions can lead to fatigue abatement. Very few studies are available on the impact of shot peening on fatigue life of near beta titanium alloys [1, 2]. In order to improve our understanding and to optimize shot peening of near Beta titanium alloys, a DOE has been performed with fatigue specimens (more than 300 four points fatigue bending specimens).

© Springer Nature Singapore Pte Ltd. 2020 S. Itoh and S. Shukla (Eds.): INCASE 2019, LNME, pp. 3–9, 2020. https://doi.org/10.1007/978-981-15-0054-1_1

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C. Dides et al.

2 Material and Experiments 2.1

Material

The material used for this study is the Ti 10-2-3 which belongs to near beta alloys family [3]. 2.2

Design of Experiments

There are many parameters in shot peening: Incidence angle, velocity, shots type, Almen intensity, coverage, projection type [2]. In addition, before shot peening, the finishing operation of machining can have an influence on final fatigue life [4], in particular roughness. 5 parameters have been chosen to define optimal conditions for shot peening and surface preparation. In order to reduce the number of tests, 3 fatigue tests levels have been defined and included as a parameters of the Matrix. The other parameters have been chosen because of industrial madders. DOE parameters are presented in Table 1. Table 1. DOE parameters Roughness after machining (Ra, µm) 0.8 1.6 3.2

Stress level Level 1 Level 2 Level 3

Shot Hardness (HRC) − +

Diameter (µm) − +

Intensity (A) − +

Coverage (%) − +

In these conditions, the DOE has 144 combinations. Considering tests’ repetition to evaluate the scattering and also the additional specimens to characterize the microstructure, the amount of tests was too huge and needed to be reduced. To do so, D-optimal methods have been used to optimize the DOE leading to a reduce plan of 325 testes. 2.3

Specimens Preparation and Testing Conditions

The specimens’ geometry used for the four-points bending fatigue tests is presented on Fig. 1. Both side of specimens have been shot peened in industrial Wheelabrator machine using nozzles on a 6 axes robot. Shot peening was performed with 85° angle from the surface with a longitudinal direction displacement.

Optimization of Shot Peening for Titanium Alloys Ti 10-2-3

5

Fig. 1. Specimens shape

To start with similar microstructure, all specimens have been picked-up at mid radius of a billet. Face A corresponds to the face close to mid radius (see Fig. 2). The three roughness specified in the DOE Ra = 0.8/1.6/3.2 are related to different machining conditions.

Face A

Fig. 2. Cut plan for 4 points bending fatigue

All fatigue tests have been performed with the following conditions: – Ratio: R = 0.1 – Controlled in maximum stress level – Frequency: 10 Hz Results analysis has been performed with Minitab software.

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3 Results Prior to shot peening test plan, several fatigue tests were launched on specimens before shot peening with different surface roughness to establish the reference. These results are plotted in Fig. 3.

Fig. 3. Wölher curve of Ti 10-2-3 with three different surface roughness

It can be seen that surface roughness doesn’t seem to have significant effect on lifetime. Close to the endurance scattering is more important and the impact of roughness is difficult to quantify. The three stress levels used for the DOE have been defined according to the reference testes in order to represent different parts of the Wöhler curve. Stress level close to endurance is avoided to present too much non-failed specimens, which couldn’t be used for the analysis. Pareto diagram has been used to evaluate the relative impact of each of parameter, or combination of parameters, on fatigue life (Fig. 4). This analysis shows that the parameters, or combination of parameters, which present normalized effect above 1.981 have a significant impact on fatigue life. If it turns out that surface roughness before shot peening has very low impact on fatigue, shot parameters (diameter and hardness) and Almen intensity have much more influence on fatigue life.

Optimization of Shot Peening for Titanium Alloys Ti 10-2-3

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Diagramme de Pareto des effets normalisés (réponse : Résidus, Alpha = 0,05) 1,981

Factor

Name

A

Roughness

B

Hardness

C D BC DE CD

Terme

CE BE

C

Diameter

D

Intensity

E

Covering

AB BD A B AD AE E AC

0

1

2

3

4

5

Normalized effect

6

Fig. 4. Pareto diagram of normalized effect

In addition to Pareto analysis, the graphic of major effects represents the evolution of fatigue life with regard to parameters “low-high” limits (Fig. 5). Size has a very important impact on fatigue enhancement, shots with large diameter have a beneficial effect on fatigue life time. In contrast, the intensity has to be reduce to

Graphique des effets principaux pour Résidus Moyennes des données Hardness

Roughness

Diameter

2,5 2,0 1,5

Moyenne

1,0 0,5

-

Intensity

+

-

+

-

+ Covering

-

2,5 2,0 1,5 1,0 0,5

-

+

Fig. 5. Graphic of major effects on fatigue life time enhancement

+

8

C. Dides et al.

improve fatigue life. As it can be seen above on Pareto diagram Covering and Roughness before shot peening doesn’t have strong effect on the results observed. If Shot hardness is considering alone, it has just a few effect. Pareto diagram shows that combinations of parameters can also have a strong impact on final results. Figure 6 is the diagram of interaction between the different parameters.

-

+

+

-

-

+

-

+

4

Roughness

-+

2

Roughness

0 4

Hardness

-

2

Hardness

+

0 4

Diameter

-

2

Size

+

0 4

Intensity

2

Intensity

0

-

+

Covering

Fig. 6. Diagram of parameters interactions regarding fatigue lifetime

First observation shows that except for hardness and shots size, for each combinations, curves do not cross each other. Whatever the parameter combined with the intensity, lower value provides the best response. As for intensity, diameter seems to be more efficient with large diameters for each combination. Only the hardness is strongly affected by the diameter. Combine low hardness and high diameter shots seems to have a positive impact. Combination of covering with roughness and hardness has no impact on results. Otherwise, covering has an effect with low intensity and it seems damaging to use a too important amount of covering.

4 Conclusion Ti 10-2-3 titanium can’t be easily shot peened like most of steel. Shot peening parameters have to be chosen very carefully. Regarding the results, a low intensity with high diameter shots seems to have the best effects on fatigue behaviour. These results can be explained by the high sensitivity

Optimization of Shot Peening for Titanium Alloys Ti 10-2-3

9

of titanium to the surface integrity (roughness, residual stresses & hardening). In addition, a low Almen intensity can introduce enough residual stress without decreasing significantly the surface roughness. Experiment results with high shots size are in the same way because the more shot diameter is high, the more surface roughness is homogenous and covering is quick. More than that, using high diameter shots can reduce creation of deflect on the surface. Covering has an impact on fatigue results only for a low intensity. This observation seems to explain that high intensities seems to generate high roughness which has a more important impact on fatigue than compressive residual stresses. Besides, a too important covering downgrade the roughness and fatigue behaviour in the same way. This conclusion is consistent with some studies in the literature on fatigue behaviour of titanium parts [5]. Because some measurements haven’t been performed yet, roughness and residual stress answers are not presented in this paper but will be added in the presentation. It will allow to understand all fatigue answers and competition between roughness and residual stress on titanium alloys.

References 1. Unal, O., Cahit Karaoglani, A., Varol, R., Kobayashi, A.: Microstructure evolution and mechanical behavior of severe shot peened commercially pure titanium. Vacuum 110, 202–206 (2014) 2. Fuhr, J.P., Basha, M., Wollmann, M., Wagner, L.: Coverage and peening angle effects in shot peening on HCF performance of Ti-6Al-4V. Procedia Eng. 213, 682–690 (2018) 3. Deleuze, C., Barrallier, L., Fabre, A., Esberard, C.: 19ème Congrès Français de Mécanique, 24–28 août Marseille: Etude de la microstructure d’un alliage de titane biphasé de nuance Ti10 V-2Fe-3Al et de son influence sur l’élargissement des pics de diffraction (2009) 4. Cox, A., Herbert, S., Villain-Chastre, J.-P., Turner, S., Jackson, M.: The effect of machining and induces surface deformation on the fatigue performance of a high strength metastable Beta titanium alloy. Int. J. Fatigue 124, 26–33 (2019) 5. Yao, C., Wu, D., Ma, L., Tan, L., Zhou, Z., Zhang, J.: Surface integrity evolution and fatigue evaluation after milling mod shot-peening and polishing mode for TB6 titanium alloy. Appl. Surf. Sci. 387, 1257–1264 (2016)

Mechanical Investigations on Composite Peened Aluminium Michael Seitz1(&) and Kay André Weidenmann2 1

Karlsruhe Institute of Technology (KIT) Institute of Applied Materials (IAM-WK), Kaiserstr. 12, 76131 Karlsruhe, Germany [email protected] 2 Institute of Materials Resource Management, Augsburg University, Werner-von-Siemens-Straße 6, 86159 Augsburg, Germany

Abstract. Composite peening describes a novel approach based on the micro peening process. By composite peening, particles can be introduced into nearsurface regions of metallic base materials. The proportion of the reinforcement phase decreases gradually with increasing distance to the surface. These so-called Functionally Graded Metal Matrix Composites (FGMMC) are characterised by a multitude of different characteristics, such as material combination, particle density, particle gradient and particle size, and a resulting broad range of properties. The composite material produced by this method promises a high application potential for lightweight, wear resistant and cyclically stressed structural components. EN AW–1050 was selected as matrix material and alumina as abrasive respectively reinforcement material. Additional abrasives such as silicon carbide and tungsten carbide were also investigated. By varying the process parameters, such as temperature and pressure, the influence on the particle density and the particle gradient was evaluated. Penetration depths up to 30 µm could be observed at high homologous temperatures. The peening process might cause open structures near the surface, the sample were subsequently deep rolled. In addition, this process reduces the surface roughness. Ensuing mechanical characterisation focused on bending tests. An increase in the flexural strength of the composite material compared to the base material could be observed. Keywords: Composite peening Mechanical properties


Metal matrix composites


1 Introduction Metal matrix composites (MMCs) are characterised by increased specific properties compared to monolithic metals. Due to their low thermal expansion and increased creep resistance, MMCs promise superior properties even at elevated temperatures. Further applications are also conceivable in the field of fatigue and tribology. Since the highest loads often occur locally in a component, the material efficiency can be improved by reinforcing the surface layer. These so-called functionally graded metal matrix © Springer Nature Singapore Pte Ltd. 2020 S. Itoh and S. Shukla (Eds.): INCASE 2019, LNME, pp. 10–18, 2020. https://doi.org/10.1007/978-981-15-0054-1_2

Mechanical Investigations on Composite Peened Aluminium

11

composites (FGMMCs) have a large number of possible modifications (for instance, material combination, particle density, particle gradient) and resulting properties. The range of manufacturing possibilities for graded MMCs is large. Therefore, a distinction is made between constitutive, homogenizing and segregating processes [1]. All processes are united by a high degree of complexity in terms of processing. In the best case, subsequent changes are associated with a huge additional effort. Exceptions are coating processes such as laser beam dispersing [2] and cold spraying [3, 4]. Shot peening is used as a standard mechanical surface treatment process. At the beginning of the 1990s, micro peening developed from conventional shot peening with significantly smaller blasting particles [5]. Compared to conventional shot peening, a lower roughness and an increased fatigue strength are achieved [6, 7]. Ando et al. has shown that it is also possible to implement blasting particles into the surface of the target material by micro peening [8]. As a result, the micro hardness could be increased. By heating the target material to high homologous temperatures, it is possible to get the blasting media much deeper into the base material, as the authors have shown with aluminium and tin [9, 10].

2 Experimental 2.1

Materials

In this study, the aluminium alloy EN AW-1050 is selected as the matrix material. The chemical composition of the alloy is listed in Table 1. Table 1. Chemical composition of EN AW–1050 Al Si Fe Cu Mn Mg Ti Zn EN AW–1050 99.52 0.10 0.30