UET TAXILA

Failure of Engineering Materials & Structures MECHNICAL

ENGINEERING
DEPARTMENT
Code 02

Effect of Shot Peening on the Fatigue Life of

2024 Aluminum Alloy
Arshad Mehmood and M. M. I. Hammouda

Department of Mechanical Engineering, University of Engineering & Technology Taxila-Pakistan

ABSTRACT Experimental study of the effect of shot peening parameters such as shot size,
nozzle pressure, nozzle distance, impingement angle and exposure time on high strength
aluminium alloy ASTM 2024 mostly used in air craft industries for cyclic loading applications
has been presented. In the first part of research work, following the standard procedure, effect of
peening parameters on the Almen strip and finally on the fatigue test specimens was studied.
Surface texture changes occurred due to peening was examined using powerful optical
microscope. Peening process also led to the formation of compressive residual stresses in the
surface layer and was determined using hole drilling method. Based on the results, a set of
optimum peening parameters was evolved. Machined (unpeened) specimens and peened
specimen were tested using four point rotating bending fatigue testing machine to generate the
SN-curves. The results indicated a considerable improvement in the fatigue life of peened
specimens when compared with the fatigue life of unpeened specimens.

INTRODUCTION

Shot peening is a well-established cold working process, widely used in automotive and aircraft
industries. [1] The technique involves the impingement of a stream of spherical shots, directed at
the metal surface at high velocity under controlled conditions [2, 14]. The process has useful
applications in increasing fatigue strength, relieving tensile stresses that contribute to stress-
corrosion cracking, forming and straightening of metal parts, and testing the adhesion of silver
plates on steel [2,12].

Shot peening generates plastic deformation in the exposed surface layer and, thus, induces
compressive residual stresses in that layer [14]. Thus, an improvement in the fatigue strength of
shot peened components is commonly reported in the literature [1, 7, 9, 10, 16, 20]. Such an
effect depends on the variables of the process, i.e. shot size, nozzle pressure, impingement angle,
shot flow rate and nozzle distance from the specimen surface. Those variables are integrated in
the form of Almen intensity [3, 7,10,16,]

Aerospace industry has a particular interest in aluminum alloys. Examples of relevant peened
parts include fuselage skin, wing ribs, bulkheads, landing gear beam and wing lower skin of air
 Arshad Mehmood and M. M. I. Hammouda FEMS (2007) 02 2

crafts. Helicopter rotor blades and some parts of their drive elements, high-pressure turbine and
compressor discs are other examples. Some of those parts are made of Aluminum alloy 2024.

Fatigue life against shot peening of specimens made of aluminum alloys was experimentally
investigated [12, 13, 16-17]. There are reports indicating variations in the fatigue life for peened
components.

References [1, 7, 9, 10, 16, 20] have shown that shot peening has beneficial effects on the
different grades of alluminium alloys.
On the other hand studies [4] have shown that steel shot peening (steel shot diameter between
0.35 and 0.7 mm to an Alman intensity of 0.010A, per SAE J442 standard) did not result in an
increase in the fatigue endurance of aluminium alloy.

In some cases the fatigue limit of the shot peened specimens fell below that of the un-peened
specimens. For example studies [6] have shown that steel shot peening with shot S 110 and S280
as per SAE J442 standard has decreased the fatigue life of aluminium alloys. [6]

For the best results, it is essential to optimize the various peening parameters. Analysis of the
shot peening variables in terms of the total energy of the shot stream shows that for a given
material being peened, a maximum value of surface stress is reached and stays constant over a
wide range of energies. An optimum value of shot stream energy exists to obtain maximum
fatigue life. This is related to shot size and flow rate through the physical effects of the shot
impacting the work surface [7].

The results of different worldwide research works presented above indicates the importance of
process quality control and peening parameters in peening aluminium alloys in terms of
achieving the optimum improvement in fatigue life. This is not a simple problem and a number
of parameters have to be carefully controlled to maximize fatigue life. These include peening
media (Shot size, shot material, shot quality), pressure /velocity, Exposure time, peening distance
etc. [1].

These references (4-7, 11-12) reveal that shot peening process depends upon peening condition
or peening parameters. But it remains unclear how these parameters affect the peening quality
and what are the optimum peening conditions for Alluminium alloys. Also, these inconsistent
reports do not provide the high level of confidence required for the industrial adaptation of the
process in the basic design considerations as long as fatigue strength is concerned. Detailed
literature review and above presented results highlights further research areas and may be
considered sufficient justification to the selected research work. The research undertaken will
provide a good understanding of peening process, optimum peening parameters affecting the
fatigue life of aluminum alloys and residual stress measurement.

EXPERIMENTAL WORK

Material and Specimen

The material in the present work was 2024 Aluminium alloy ASTM-B211. Table 1 lists the

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mechanical properties of the tested material. The corresponding chemical composition in weight
% was as follows: 0.1 Cr, 2.0 Cu, 0.5 Fe, 1.5 Mg, 0.6 Mn, 0.05 Si, 0.15 Ti, 0.25 Zn and
remaining Al. Fig.1 shows the geometry of the present fatigue test specimen as per ASTM
standard E606 [15]. Forty-five of such specimens were tested to obtain their S/Nf curve in both
condition of as machined and after purposely-designed shot peening.

Table 1 Mechanical properties of Aluminium 2024 ASTM-B211

0.2 % Ultimate Elongation Possion’s Elasticity Brinell

Proof tensile stress % ratio modulus Hardness
stress MPa GPa
MPa
324 393 20 0.33 73.1 120

Fig. 1 Geometry of the present test specimen

Evaluation of Almen Intensity

Shots of three sizes were applied for this process. Their material / hardness are listed below in
table 2. Experimental work started from peening machine. An air blast machine of 136 MPa
pressure rating was selected for the test work. The air blast nozzle internal diameter (6mm) was
checked using a standard go-no go gauge before testing. Shot flow rates were calibrated using
real time catch tests. The nozzle to test strip / specimen center location was adjusted and was
checked before and after testing, the shot impact angle on the test strips was calibrated and
checked before and after testing protractor/level. Peening strips of size 3”x 0.75”x 0.031” thick
(type A) as per SAE J442 arranged. “A” scale / type Almen strip is recommended for low
intensities which are normally used for soft materials like aluminum [3]. Three standard sizes
for strips of material SAE 1070 spring steel are used and “A” scale type is shown in the fig.2
[14]

Each strip was individually inspected for flatness using an Almen Gage #2. All strips with a
tolerance of less than or equal to 0.0001 inch were selected for use. All strip mountings and
removals were done using a systematic method. These strips were

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Table 2 Peening Media Properties [14]

S.No SAE No. Ø (inches) Material Hardness (HRC)

01 S110 0.0197 Cast steel 45
03 S170 0.0280 Cast steel 45
04 S230 0.0394 Cast steel 45

Fig.2 “A” Type Almen Strip

screwed on a solid block and then on the perforated plate of the peening machine as shown in the
fig. 3 [14]

Several experiments were performed on Almen strips. Each individual peening process
parameter (like shot size, nozzle pressure, impingement angle, exposure time and nozzle
distance from the specimen) was varied to determine the relationship with almen height. During
each experiment other parameters were kept constant. Finally we were left with individual
parameter Almen intensity and its affect on the fatigue life of actual specimen were
experimentally determined.

Peening of fatigue test specimen

The same procedure was adopted for the peening of fatigue test specimen as described for Almen
strip. Following parameters were selected for the peening of fatigue test specimen.

Process variables Nominal setting

Nozzle pressure 60-80 psi
Nozzle internal diameter 6mm
Shot sizes: S-110, S-170, and
S-230
Nozzle to specimen distance 7 inches
Shot impact angle: 65°
Specimen motion 25 rpm

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Fig.3 Almen Strip Holder

Fatigue Testing

The fatigue test programme was carried out utilizing a four points rotating bending machine of
20kg-m maximum bending moment and 2860 rpm speed .The preliminary investigations
concentrated on establishing base line information regarding the fatigue life of the material. In
the main part of the programme as machined and shot peened specimens were utilized and SN
curves were determined with the view of examining the effects on peening parameters on the
fatigue life in the presence of alternating stresses. All tests were performed with the load ratio of
R = -1

RESULTS AND DISCUSSION

Results of the first part of experimental work are related to the evaluation of Almen intensity,
which depends on different variables like air pressure, impingement angle, nozzle distance and
shot flow rate. Relationship between each individual variable and Almen intensity was obtained
by keeping the other three parameters constant and are mentioned on each graph.

In fig. 4 nozzle pressure versus Almen height graph is shown. Air pressure exhibited nearly
linear behavior regarding intensity until the maximum value is obtained. The combined effect of
peening parameters appears in the from of Almen height which is the indication of absorbed
energy in the almen strips. It is obvious that higher pressure causes higher values of shot
velocities and hence more energy will be transmitted, consequently higher values of almen
intensities will appear. Effect of nozzle pressure is related to shot sizes. Larger shots give higher
almen intensities than that of smaller shots. Up to certain value of pressure almen height
increases and then once again curve bows down. It can be concluded that optimum value of
pressure exists somewhere and can be achieved.

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In fig.5 relationship between nozzle angle and Almen height is shown. Nozzle angle had the
greatest effect on intensity. Changes in nozzle / impingement angles have a pronounced effect at
low angles and very little effect at angles greater than 65º. At low angles, this effect is almost
parabolic, implying the lower the angle, the greater the effect.

The high velocity shots stream imparts energy in the peening strip. Between 0º and 90º shot
velocity is resolved into two components i.e. normal and horizontal. According to Hertzian
pressure [21] the normal component of shot velocity produces impact load which causes a
maximum shear stress below the surface and it has key role as far as Almen intensity is
concerned. As impingement angle increases normal component increases and its effect reaches
certain maximum value and after that the curve is almost horizontal. It can be concluded that the
value of normal component of shot velocity has maximum effect at 65º and after that up to 90º
this effect is almost negligible.

Fig.6 shows that Almen height increases by increasing the nozzle distance until the maximum
value is achieved and after that value Almen height once again decreases. But it can be
concluded that overall effect of nozzle distance is limited and is inversely proportional. At
smaller nozzle distances and larger distances shot stream can not produce the desired effect.
Fig.7 shows that media flow rate is inversely proportional to the intensity.

Table 3 Residual Stresses Measurement

S.No Almen Residual Stress Depth Residual Stress Depth

Intensity (Max.) MPa (mm) (Min.) MPa (mm)
01 8A -219 0.2 40 0.5
02 10A -230 0.4 45 0.5
03 12A -242 0.2 49 1.4

Microstructure changes occurred due to shot peening were also examined using powerful optical
microscope. In fig.7 and fig. 8 microphotographs of as machined and peened specimens are
shown. It can be visualized that peening has produced indentation / compression in the specimen
and has spread material near the impact point against the resistance of neighboring material, thus
introducing a complex sub-surface residual stress distribution in which generally, the surface is
in elastic compression. Stresses produced due to peening were determined by hole drilling
method shown in the table: 3 [14]

In the second part of experimental work effect of shot peening on the fatigue life of aluminium
2024 is determined. Peening process produces residual stresses in the surface layers of peened
specimens. A comparison between as machined and shot peened specimens is shown in fig.8 and
9. Microphotographs of machined (before shot peening) and after peened were obtained using
powerful microscope. Each shot acts like a hammer and produces residual stresses in the surface
and subsurface layers. It can be visualized that peening has produced indentation / compression
in the specimen and has spread material near the impact point against the resistance of

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neighboring material, thus introducing a complex sub-surface residual stress distribution in

which generally, the surface is in elastic compression. Stresses produced due to peening has been
determined using hole drilling technique and shown in table 3. For higher values of Alemen
intensity value of residual stresses will be higher.

0.014

0.012
Almen height (inches)

0.01

0.008

0.006

0.004 S-110 Nozzle angle 90°

S-170 Nozzle distance 7"
0.002 Flow rate 10 lb/sec
S-230
0
20 30 40 50 60 70 80 90

Nozzle pressure (psi)

Fig.4 Nozzle pressure vs. Almen height

0.014

0.012

0.01
Almen height (Inches)

0.008

0.006

0.004 Nozzle pressure 70 psi

S110 Nozzle angle 65 °
0.002
S170 Nozzle distance 7"
S230

0
25° 35° 45° 55° 65° 75° 90°
Nozzle Angle (degree)

Fig.5 Nozzle angle vs Almen height

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0.014

Almen height (Inches) 0.012

0.01

0.008

0.006

0.004
S-110 Nozzle pressure 70 psi
S-170 Nozzle angle 65°
0.002 S-230
Flow rate 10 lb/sec
0
3 5 7 9 10
Nozzle Distance (Inches)

Fig.6 Nozzle distance vs. Almen height

0.016
0.014
Almen height (inhes)

0.012
0.01
0.008
0.006
0.004 S-110 Nozzle pressure 70 psi
S-170 Nozzle angle 65°.
0.002 S-230 Nozzle distance 7"
0
0 5 10 15 20 25
Shot flow rate (lb/sec)

Fig.7 Shot flow rate vs. Almen height

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Fig.8 Microphotograph of machine Fig.9 Microphotograph of peened

surface with 50x magnification. surface with 50x magnification

Considerable improvement in the fatigue life of peened component was observed. In table 4
results of as machined and shot peened specimens are shown. 166 % improvement has occurred
due to shot peening at the cyclic stress of 60 % of the UTS. This is because of residual stresses
produced by shot peening. These stresses slow down crack propagation rate.

At lower stress values fatigue life improvement will be more as compared to higher stress values.
As cracks propagation rate is higher at higher stress values.

Almen intensity is the major parameter on which fatigue life of the specimen depends. Number
of cycles versus Almen height graph shows that up to certain value of Almen intensity, number
of cycles increases and then curve bows down even by increasing the Almen height. This may be
due to the residual stress value that should be optimized otherwise peening may produce adverse
effects.

Table 4 Fatigue life comparison of as machined and 12A-shot peened specimen at

an applied stress of 250 MPa (63% , 38% of UTS)

σb / W As machined Average Peened-12A Average

S.No MPa-Kg Nf Nf Nf Nf Gain %(Gain)
.
01 1.145 x 104 4.85x 105
02 250/ 66 2.40 x 104 1.898x 4.70 x 105 5.06x 104 3.1x104 166%
03 1.80 x 104 104 4.23 x 105
04 2.25 x 104 6.46 x 105
01 150/40 1.25 x 8.3 x 105 6.05 x 484%
105 105

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The fatigue life that can be visualized from fig.10. This is because of compressive residual
stresses. Larger size media produces more residual stresses than the smaller one which may
decrease the fatigue life of specimens. Almen intensity can be optimized from the results of
figure: 11. Up to certain value of Almen intensity fatigue life increases and after 12A it once
again decreases. Hence 12A can be considered optimized value of Almen intensity.

400
Peened
350
unpeened

300
Cyclic stress (MPa)

250

200

150
Nozzle pressure 70psi
100 Shot size S110
Nozzle distance 7"
50 Nozzle angle 650
Flow rate 10.5 lb/sec
0
1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Log (Nf )

Fig. 10 SN curves comparing the fatigue life of unpeened and 12A peened specimens

2.00E+05
0.012
0.01

1.50E+05 0.008
No. of cycles (Nf)

0.005 0.014

1.00E+05 0

Nozzle Pressure 70Psi

Shot size S110
5.00E+04 Nozzle distance 7"
Nozzle angle 650
Flow rate 10.5 lb/sec
Bending stress 225 MPa
0.00E+00
0 0.005 0.01 0.015
Almen Height (Inches)

Fig.11 Almen height versus average no. of cycles to failure

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CONCLUSIONS

The effect of shot peening on fatigue life of the 2024 Aluminium alloy was studied under
constant amplitude loading condition .The results showed that shot peening can be applied to
increase the fatigue life of the alluminium alloy under optimum conditions otherwise we may not
get the appropriate results and even it may cause adverse effects. Also the beneficial effect of the
process is greater at long fatigue lives than at short fatigue lives.

1. Air pressure exhibits nearly linear behavior regarding intensity until the maximum
intensity for a particular media size is achieved. Higher intensities can be obtained at
lower pressure for large size shots.
2. Nozzle angle had the greatest effect on intensity. Changes in nozzle/impingement angles
have a pronounced effect at low angles and very little effect at angles greater than 55º for
small shots and 65º for large diameter shots.
3. Nozzle distance has a limited effect on intensity and media flow rates is inversely
proportional to the intensity. Value of Almen intensity increases as media size increases.
4. Larger size shots produce more residual stresses in the surface layers of the specimen as
compared to smaller size shots and smaller shots are more effective than the larger shots.
5. Optimum value of the peening intensity exists between 8A to 13A for alluminium alloys

ACKNOWLEDGEMENTS

National Institute of Science and Technical Education, Islamabad.

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