Effect of Intensity, Coverage and Angle of the Shot Peening to Compressive

Residual Stress in Aluminum Al-2024 with X-ray Diffraction

R. Henny M1,a), Dini Apriliani2,b), Luthfi Vanensa3,c),

and sutarno4,d)
1-4Department of Metallurgical Engineering-Faculty of Engineering, University of Jenderal Achmad Yani (UNJANI)
Bandung, Jl. Terusan Jenderal Gatot Subroto, PO.BOX 807 (PINDAD) Bandung 40285 Indonesia.

a)
Corresponding author: [email protected]
b)
[email protected]; c)[email protected]; d) [email protected]

Abstract. Shot peening is an integral part of the process of production of structural aircraft parts are exposed to dynamic
loads during flight. The aim of shot peening is to compensate for imperfections parts during fabrication and improve the
fatigue life, stress corrosion cracking and also crack retardation. Each structural parts has geometry complex, which is
consist of rib, stringer, radius, holes and thickness. The impact of difference of peening angle will produce of various
compressive layer, surface hardness and compressive residual stress. In the study was used steel shot size 280 with angle
of peening flat, horizontal and vertical, specimens Al-2024, intensity in range of 0.006-0.01A and 100% and 200%
coverage. Peening time is determined by almen strip A, by variating peening time at the constant pressure than create curve
of saturation peening time, which is deferent intensity less than 10% at the peening time twice. The results are include the
depth compressive layer of 22.49-45.19 m, surface roughness 2.43-3.55 Ra, hardness 192-289 HVN and for 100%
coverage and 32.15-54.54 m, surface roughness 2.31-3.33 Ra, hardness 192-237 HVN for 200% coverage. While the
compressive residual stress result for coverage of 100% and 200% and the intensity 0.006-0.011A was 235-325 MPa.

Keywords: Shot peening, intensity and coverage, compressive residual stress

1. INTRODUCTION
1.1. Background
In an effort to prevent fatigue, fracture and corrosion failure that affect the function and service life of critical parts
or even a system, usually in manufacturing parts such as aircraft structural, blades, rotor spindles, landing gear
components, springs, gears, connecting rods, camshafts added shot peening operation The addition of shot peening
operation aims to introduce a layer of residual compressive stress press and capable of preventing the rate of crack
propagation at the notch, scratches and other surface defects as well as stress corrosion cracking during services. Since
1950s the discovery that shot peening a sheet metal can curve it actually brought shot peening to another important
application such as shot peen forming, corrective peen forming which has been mainly used in the aircraft industries.
Shot peening is a surface treatment engineering by way of striking a steel ball or glass bead or alumina to the
surface of the parts with controlled speed. The striking a steel ball caused dimple on the surface followed by plastic
deformation and strain hardening. The amount dimple will be affected by the hardness of the material parts and steel
ball velocity. When the collision took place at the same velocity with a certain amount of steel balls and repeated it
will produce dimple rough, hard and compressive stress layer and residual compressive stress in the subsurface parts.
Surface roughness will decrease with an increase in collisions, while the hardness, compressive residual compressive
stress layer and relatively unchanged. This layer of compressive residual stress retard to the crack propagation which
usually initiates from the surface and becomes the source of fatigue and fracture failure of the parts.
The aims of the research is to evaluate the effect of intensity, coverage and angle of the shot peening to compressive
residual stress in aluminum Al-2024 with X-ray Diffraction. In addition, the results also shot peening hardness surface
roughness characteristics at peening intensities of 0.006 – 0.01A with coverage of 100% and 200%. The shot peeing
operation perform on automatic shot peening machine with steel ball made from cast steel #280. Prior to shot peen
operation is determined the shot peen time at saturation curve condition by using almen test strip, which is made from
material SAE 1070 cold rolled spring steel with hardness 44-52 HRC. Saturation curve is intensity when the exposure
time for the almen strip test is double, the arc height does not increase by more than 10% with note that the The arc
height at saturation for each location must be within the required arc height range for that location.

1.2. Mechanism of shot peening

If the steel ball with mass 4/3 R3 and given acceleration, is bombarded on surface of part can be written
as equation (1)
4 v
R 3 = −a 2 P (1)
3 t
Where P is pressure that occur on the surface of part and a2 is dimple area due to controlled velocity of shot.
Relation among P and modulus young, E and also yield stress, σ y will be formulated as shown on equation (2),

 2 Ea 
P =  0.6 + ln y (2)
 3  y R 

Due to repeated the bombardirment of shot to surface of parts, P will be replaced with equation (3)
 
 6 m3 RE 
 1 −  2 0.2
0.407
p=  (3)
a 2  1+ R 
 Rc 

Control intensity will be performed by using almen strip type A

1.3. Critical factors of shot peen
In the shot peening operation, many of the process parameters that must be controlled in order to produce quality
peening that meets to the specification requirements. Some operating parameters such as shot flow rate, shot speed
and shot diameter which affect the intensity and peening time, while the coverage is determined by the condition of
repetition with the same parameters.
Based on the intensity, peening time and coverage obtained characteristics such as surface roughness, hardness,
compressive residual compressive stress layer and which affect the fatigue, fracture and corrosion failure of a parts,
components and even system. The magnitudes of the residual stresses and the depth of the layer containing these
stresses are a function of the process parameters set for the operation such as intensity, angle, coverage and shot size.
1.3.1. Angle of peening
As is known, a structural parts have complex geometries that form the angle of peening. The angle of shot peen
influence in the magnitude of the dimple that affect the surface
roughness and hardess, plastic deformation, strain hardening,
compressive layer and also the residual compressive stress, all of the
which have an impact on fatigue, fracture and corrosion failure parts.
For example, differences in compressive layer, wherein the residual
compressive stress there will retard to the crack propagation is
usually preceded by a crack, scratch or indentation.
To ensure that the quality of the shot peening can meet the
specification requirements, required the development of a method
associated with the geometry of parts to be bombarded by shot
peening based on the angle. Through the installation of Almen strips
in various configurations angles peening as a representation of the geometry of parts can be determined angle impeller
machining, speed shot that will be verified by the intensity and coverage can be achieved on critical areas where high
tensile stresses or stress ranges are most likely to cause fatigue or stress corrosion failures in service.
1.3.2. Intensity and coverage
 Magnitude intensity of peening is measured by the arc height of Almen strip, which plays an important role in the
formation of the compressive layer and compressive residual stress. The amount of the arc height, expressed as a
saturation F

(4)
Where Arc height among others influenced by the density, velocity, pressure, while coverage and peening time is
expressed by the equation
(5)
Where n is the number of cycles peening and C1 is the first peening coverage cyclus. The rise cycle will affect the
surface roughness and compressive layer.
1.3.3. Compressive residual stress
Residual stress can be either compression or tension stress on the parts after the no apllied stress. In mathematics,
the residual stress is expressed as
(6)

Where R, C and T, respectively is residual stress, compressive stress (-) and applied stress (+). When R less
than 0, then the residual stress is compressive residual stress which affects the increase in fatigue life of a parts or
components of a system.
Plastic deformation due to shot peening causes the distance between the crystal planes changed. Compressive
residual stress shot peening results of the operation were measured using XRD with a wavelength of between 0.5-2.5.
The relationship between the wavelength spacing of crystal planes Bragg stated in the law. Calculation of compressive
residual stress is expressed as [qulity]

(7)

For aluminium, Al2024T351 the value of E/(1+v) is 53.8 GPa,

2. EXPERIMENTAL PROCEDURE

2.1. Design of experiment

The raw materials to be used in the research are Al2024 T3 with intensity between 0.006-0.010 and coverage 100%
and 200% and angle position flat, horizontal, vertical as shown in Table 1.
No Material Coverage Intensity Angle (degree)
1 2024T3 100% 0.0096 Flat (90)
2 2024T3 100% 0.008 Horizontal (60)
3 2024T3 100% 0.0068 Vertical (30)
4 2024T3 200% 0.011 Flat (90)
5 2024T3 200% 0.0087 Horizontal (60)
6 2024T3 200% 0.0074 Vertical (30)

2.2. Experiment procedure

Experiment conducted at Spencer Machine automatic speed of 8 mm/second, using steel shot # 280 with a flow
rate shot 7200 kg / hour. Prior to performing shot peen operation, intensity and time of shot peen is determined by
using the saturation curve.
 3. RESULT AND DISCUSSION
3.1. Compilation and characterization
Characterize of shot peen result includes the measurement of surface roughness, hardness, and compressive
residual compressive stress layer. Furthermore, the data is processed with a graphic that gives the correlation between
the parameter-process with the characteristic and the correlation between characteristics.
Table 2. Compilation and characterization of shot peen result
Depth of Residual
Coverage Intensity Roughness Hardness
No. specimen Angle (o) compressive stress
(%) (A) (µm/Ra) (HV)
layer (µm) (MPa)
Flat
1 F1 100% 0.0096
(90)
3.55 228.87 45.19 -292
Horizontal
2 H1 0.0080
(30◦)
3.13 221.58 37.66 -282
Vertical
3 V1 0.0068
(60)
2.43 192.61 22.49 -269
4 F2 200% 0.0110 Flat (90) 3.33 237.28 54.54 -325
Horizontal
5 H2 0.0087
(30)
2.73 225.60 38.53 -300
Vertical
6 V2 0.0074
( 60)
2.31 192.58 32.15 -235

3.2. Effect Angle of peening to intensity

Berdasarkan Fig. 2, angle of peening 90o
memberikan intensity tertinggi, selanjutnya 30o (60o
based on shot) dan 60o (30o based on shot) untuk
coverage yang sama. Sedangkan untuk coverage 200%
memberikan intesity yang lebih tinggi dibanding
coverage 100%.
Angle of peening terhadap konfigurati parts
mengakibatkan compressive layer berbeda yang secara
otomatis dihasilkan compressive residual stress juga
berbeda. Dalam prakteknya perbedaan harus dijaga
pada rentang 0.006 -0.01A
to intensity
3.3. Effect peening intensity to characteristics
Effect peening intensity to surface roughness and hardness at the coverage of 100% and 200% as shown in Fig. 3.
Based Fig. 3 looks at the rise peening intensity is directly proportional to the increase in hardness and roughness. At
the same intensity, coverage 100% give higher roughness compared with 200% coverage. While the change in
hardness at the coverage of 100% and 200% is almost no significan. In other words, the changes only affect surface
coverage rouhness and no impact to the surface hardness. In practice, to achieve the requirements of surface roughness
done with sandpaper smoothing as needed permitted. The purpose of refining the surface of this is to prevent the loss
of compressive layer and once the initial crack, which affect the fatigue failure.
 Fig. 3. Effect intensity to surface roughness and hardness at deference coverage
Mechanism of fatigue failures consist of initiation of the crack at a surface that has either residual tensile stresses
or applied tensile stresses, crack propagation is crack growth due to applied of cycle loading and termination. In
otherword by additional shot peening operation on surface of parts the fatigue crack can be retarded.
3.4. Effect peening intensity to depth of compressive layer
The results are the depth compressive layer of 22.49-45.19 m for 100% coverage and 32.15-54.54 m for 200%
coverage. In general, the depth of the compressive layer is affected by the hardness and intensity peening. In this
research with the intensity obtained by the angle of peening (as described in Fig. 2) of the same and coverage of 100%
and 200% shows the depth of compressive layer as shown in Fig. 4. According to Fig. 4, for a coverage of 200% with
the same angle of peening provide different peening intensity that is 0.011A, while the coverage of 100% only gives
the intensity of 0.0097A.

Fig. 4. Effect intensity to compressive layer

Thus, the increase is in the coverage angle of the same peening will affect the increase is in the depth of compressive
layer and smoothing the surface of the parts, the which directly improved fatigue life. However, in practice for complex
geometry parts, the peening intensity difference should be within tolerances specified in spesification customer, for
example in the range 0.006-0.001A.
3.5. Effect peening intensity to residual compressive stress
The main objective of the operation is the introduction of shot peen compressive residual stress critical structural
parts and components of a system that has the function and lifespan in accordance with design requirements. Based
on the calculation of the residual compressive stress for Al-2024T3 aluminum as shown by Fig. 5.

Fig. 5. Compressive residual stress to depth of compressive layer at deference coverage

The results are include the depth compressive layer of 22.49-45.19 m for 100% coverage and 32.15-54.54 m for
200% coverage. While the compressive residual stress result for coverage of 100% and 200% and the intensity 0.006-
0.011A was 235-325 MPa.

CONCLUSION

Shot peening process has been applied on a critical structural parts for aircraft, turbines, engines and landing gear,
and so on. Along with the configuration and geometry of critical structural parts of the complex, the necessary angle
of peening the right, so that the determined intensity and peeing time to produce compressive residual compressive
stress layer and which meet the requirements of engineering drawing.
The difference angle of peening impact on the depth of compressive residual compressive stress layer and in
practice is permitted when the intensity is in the range 0.006A-0.01A.
The results are include the depth compressive layer of 22.49-45.19 m, surface roughness 2.43-3.55 Ra, hardness
192-289 HVN and for 100% coverage and 32.15-54.54 m, surface roughness 2.31-3.33 Ra, hardness 192-237
HVN for 200% coverage. While the compressive residual stress result for coverage of 100% and 200% and the
intensity 0.006-0.011A was 235-325
ACKNOWLEDGEMENT
On this occasion the authors expressed high appreciation to PT Dirgantara Indonesia, which has given permission
to conduct research shot peening process. Awards were also presented to the Dean of the Faculty of Engineering of
the University General Achmad Yani (UNJANI) for their support, especially in funding.

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