Almen Intensity Effect On Microstructure PDF
Almen Intensity Effect On Microstructure PDF
a r t i c l e
i n f o
Article history:
Received 8 September 2013
Received in revised form 30 October 2013
Accepted 31 October 2013
Available online 21 November 2013
Keywords:
Shot peening
Ultra ne grain
Nanoindentation
Almen intensity
Residual stress
a b s t r a c t
This paper discusses alteration of microstructure and mechanical properties of low carbon steel after
severe shot peening process. An ultra ne grained surface layer was formed on AISI 1017 mild steel by
means of severe shot peening process. Surface characteristics were afrmed using optical microscopy,
scanning electron microscopy (SEM) and high resolution transmission electron microscopy (HRTEM).
Nano hardness measurements were taken along the depth from shot peened surface using nanoindentation methods. The results showed that severe (unconventional) air blast shot peening process is an
effective way to obtain ultra ne grained surface layer and to obtain superior mechanical properties.
2013 Elsevier B.V. All rights reserved.
1. Introduction
In recent years, ultra ne grained structures or nano crystallized
structure formations have attracted considerable scientic interest
[1]. There are several methods to create nanostructured materials.
Nevertheless, these methods are classied according to the materials. The materials are (1) bulk nanostructured materials and (2)
bulk materials with a nonastructured surface. Bulk nanostructured materials possess nanostructured layers completely. However,
bulk materials with a nanostructured surface have coarse grained
interior with a nanostructured surface. Bulk nanostructured materials are accomplished by either bottom-up (assembly of atoms into
nanoscale cluster by consolidation) methods or top-down (obtain
nanostructure by structural decomposition) methods [2]. Equal
channel angular pressing (ECAP), high pressure torsion (HPT) and
constrained groove pressing (CGP) can be classied into top-down
methods for performing bulk nanostructured materials. For the
bulk materials with a nanostructured surface, air blast shot peening [3], high energy shot peening [4], ultrasonic impact peening
[5], high speed machining particularly drilling [6] can be applied
as top-down methods. Severe plastic deformation (SPD) methods are expressed as increasing defects and grain boundaries with
Corresponding author. Tel.: +90 378 223 53 65; fax: +90 378 223 53 58.
E-mail addresses: ounal@bartin.edu.tr, unalokan78@gmail.com,
okanunal78s@hotmail.com (O. Unal), remzivarol@sdu.edu.tr (R. Varol).
0169-4332/$ see front matter 2013 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.apsusc.2013.10.184
in different bulk metals and alloys, which have different crystallographic structures. Coarse grained to ultra ne grained conversion
mechanism is still in an ongoing research. Studies depict that short
and long range shear bands emerge after exposing the materials to
plastic deformation. Shear bands play a major role at grain subdivision local dynamic recovery and recrystallization processes.
Large deformations lead to generation of a distinct structure of
dislocation-free and highly misoriented ne grains with high angle
grain boundaries (HAGB) [14].
The severe shot peened specimens are classied as bulk materials with ultra ne (nanostructure) grained surface and coarse grain
interior as mentioned before. Nevertheless, materials subjected to
severe plastic deformation methods such as ECAP or HPT are named
as bulk nanostructured materials. Both the methods are based upon
the high plastic deformation and they attribute distinct mechanical
and physical properties to the materials [15]. Actually, it may not be
necessary in any case to obtain ultra ne grained structure of whole
material. Fatigue, fretting fatigue, wear and corrosion failures originate from surface and propagate [16,17]. So obtaining ultra ne
grained structure on the surface and just below the surface can slow
down or prevent crack propagation. A machine part with a nanostructured surface layer and coarse grained interior is expected to
have highly improved fatigue properties. So, both fatigue-crack initiation and propagation are inhibited by ne grains near the surface
and the coarse grains in the interior, respectively [18].
Air blast shot peening is a cold working process generating high
plastic deformation on the surface of metals in recent years also
this process has been applied to ceramics for retarding the crack
propagation [19]. This mechanical surface treatment compensates
the requirements such as hardness, strength and considerable
resistance to fatigue failure in service conditions. In the last few
decades, large efforts have been performed on microstructure
change of the surface layer with different types of shot peening
techniques. Therefore, the effect of shot peening on the micro structure and mechanical properties on the surface have been examined
effectively [20]. Shot peening effect on the materials have been
investigated by means of shot peening parameters, for instance surface coverage, shot velocity and etc. [21]. Also one of the valuable
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Table 1
Almen intensity and peening parameters of each shot peened specimens.
Specimen no.
Almen intensity
Shot size
Coverage (%)
Time (sn)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
A2426
A2426
A2830
A2830
A3032
A3032
A3032
A3032
A3234
A3234
A3234
A3234
A3436
A3436
A3436
A3436
C46
C46
C46
C46
C68
C68
C68
C68
C810
C810
C810
C810
S230
S230
S110
S110
S110
S110
S230
S230
S110
S110
S230
S230
S110
S110
S230
S230
S110
S110
S230
S230
S110
S110
S230
S230
S110
S110
S230
S230
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
100
200
25
25
45
45
45
45
25
25
50
50
25
25
50
50
20
20
30
30
20
20
40
40
30
30
45
45
40
40
380 (55)
380 (55)
620 (90)
620 (90)
690 (100)
690 (100)
413 (60)
413 (60)
690 (100)
690 (100)
448 (65)
448 (65)
723 (105)
723 (105)
482 (70)
482 (70)
482 (70)
482 (70)
345 (50)
345 (50)
482 (70)
482 (70)
345 (50)
345 (50)
690 (100)
690 (100)
345 (50)
345 (50)
0.25
0.25
0.29
0.29
0.31
0.31
0.31
0.31
0.33
0.33
0.33
0.33
0.35
0.35
0.36
0.36
0.05
0.05
0.05
0.05
0.07
0.07
0.07
0.07
0.09
0.09
0.1
0.1
42
Fig. 1. (a) as received AISI 1017 specimen (b) peened with A3032 Almen intensity (c) peened with A3234 Almen intensity (d) peened with A3436 Almen intensity (e)
peened with C810 Almen intensity.
43
Table 2
Crystallite size and FWHM values of shot peened low carbon steel specimens.
Specimens
2 ()
FWHM ( )
44.78
45.04
44.79
44.92
82
44
39
38
0.120
0.219
0.243
0.250
44
Fig. 3. (a) Highly deformed oriented grains HRTEM microstructure of peened specimen with A3436 Almen intensity (b) Dislocation density due to high strain rates.
Nanohardness measurements were taken in order to investigate the inuence of plastic deformation via air blast severe shot
peening process. Nanoindentation results are depicted for peened
with C810, A3436, A3032 Almen intensity and as received specimens on Fig. 6(a). All results showed that hardness close to outmost
layer signicantly increases via severe shot peening process and
the increase on hardness from bulk material to surface is directly
related to grain renement and high dislocation density stratication. It is reasonable that from surface to interior the nanohardness
values decreased due to the reduction effect of plastic deformation.
Nevertheless, hardness decrease is not exactly correlative when
passing to interior particularly after the nanostructured zone. There
is no abrupt fall on the hardness as similar in the literature [30].
Highly plastic deformed layers may prevent the abrupt fall on the
hardness.
Fig. 6(b) shows surface hardness variation versus Almen intensity. Almen intensity and surface hardness are directly related to
each other. Hardness of the shot peened surface depends on the
rate of severe plastic deformation.
Fig. 4. Intensity distribution of all surface treated low carbon steel specimens.
Fig. 5. Surface residual stresses of the shot peened and as received specimens.
Fig. 6. (a) Hardness variation from surface to interior of peened and as received specimens (b) surface nanohardness variation according to Almen intensity.
45
46
Fig. 7. Surface roughness of peened specimens (a) A2830 Almen intensity 100% coverage (b) A2830 Almen intensity 200% coverage (c) A3436 Almen intensity 100%
coverage.
Table 3
Surface roughness (Ra , Rq , Rt ) values for peened specimens.
Almen intensity
Coverage (%)
Ra (m)
Rq (m)
Rt (m)
A2830
A2830
A3436
100
200
100
7.15
6.88
7.42
8.75
8.34
9.36
63.37
44.97
59.90
(2)
(3)
(4)
(5)
Also XRD studies show the grain sizes of the layer is below
100 nm and with the increasing of the plastic deformation rate
the grains sizes reduced to approximately 40 nm.
Besides occurrence of sub-micron ultra ne grained layer with
the increasing severe plastic deformations especially under
C Almen intensity conditions, surface micro cracks emerge.
Therefore, while determining the heavier conditions after
C810 Almen intensities, drawbacks should be taken into consideration for fatigue properties.
Due to pre-determined maximum Almen intensity C810, surface nanohardness was obtained as approximately 12 GPa.
When compared to as received specimen surface nanohardness
which is nearly 6 GPa, improvement is approximately two times
according to not peened specimen. Surface hardness enhancement is directly related to sub micron grain layer. Hardness
values reduced from surface to interior of the bulk materials.
With decreasing Almen intensity, surface hardness values are
also decreased. Approximately after 200 m thickness, severe
shot peening effect has been substantially released.
The residual stresses occurred as compressive residual stress on
the surface after the severe shot peening process as expected.
The residual stress on the surface of the specimen peened with
C810 is 310 MPa and it is just below the yield strength of
AISI 1017 low carbon steel. This result depicts the specimen
is highly plastic deformed via severe shot peening process and
approaches to yield.
47