4.5 Review

Review on Laser Shock Peening Effect on Fatigue of Powder Bed Fusion Materials

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Article Nanoscience & Nanotechnology

Enhancing the static and dynamic mechanical properties of laser powder bed fusion process built 15-5 precipitation hardening stainless steel specimens by laser shock peening

Harikrishnan Ramadas et al.

Summary: The additive manufacturing process of high strength stainless steel metallic parts by laser powder bed fusion has been successfully adopted in various high technology industries, reducing both cost and time. This study focuses on the static and dynamic mechanical properties of 15-5 precipitation hardening stainless steel in two different loading directions, and the use of laser shock peening as a post-processing tool to improve the part properties. The results show improved microhardness, tensile properties, and fatigue life with laser shock peening, making it comparable to the base specimens. This research establishes the viability of laser shock peening as a post-processing technique to mitigate the fatigue life anisotropy due to loading direction, without causing any phase changes.

MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING (2023)

Review Materials Science, Multidisciplinary

Laser Shock Peening of Laser Based Directed Energy Deposition and Powder Bed Fusion Additively Manufactured Parts: A Review

Sapam Ningthemba Singh et al.

Summary: This paper discusses the issue of tensile residual stress (TRS) in processes such as laser directed energy deposition (DED) and laser based powder bed fusion (PBF), and the use of laser shock peening (LSP) to mitigate these concerns. The basic principles and characteristics of each process, as well as popular metallic materials used in PBF and LDED processes, are discussed. The applications and drawbacks of each process are presented. Recent progress on LSP of laser based PBF/DED manufactured samples is also discussed, along with different approaches and challenges to hybrid AM + LSP. The introduction of finer grains after LSP led to an increase in microhardness and reduced pores, improving the tensile and fatigue life of the parts. Challenges and future scope are outlined.

METALS AND MATERIALS INTERNATIONAL (2023)

Article Materials Science, Coatings & Films

Laser shock wave-induced enhanced thermal corrosion resistance of Ti6Al4V alloy fabricated by laser powder bed fusion

Hairong Bian et al.

Summary: The effect of laser shock peening (LSP) on the microstructural evolution and thermal corrosion behaviors of laser powder bed fusion processed (LPBFed) Ti6Al4V samples in mixed solutions was studied. It was found that LSPed samples exhibited a thinner and denser thermal corrosion layer compared to LPBFed samples, leading to significantly reduced mass gain and improved thermal corrosion resistance. This improvement can be attributed to the presence of refined grains, high-density dislocations, and nano-twins. The mechanism of improved thermal corrosion resistance in LSPed Ti6Al4V alloy was revealed.

SURFACE & COATINGS TECHNOLOGY (2023)

Article Chemistry, Physical

Optimizing Parameters with FEM Model for 20CrMnTi Laser Shocking

Jie Sun et al.

Summary: Laser shock peening (LSP) is a novel surface treatment technology that involves multi-point overlay process of single-point laser shock. In this study, a finite element method (FEM) model of single-point laser shock was constructed and verified through experiments, with less than 20% difference in residual stresses between experimental and simulated results. The stress field and deformation of 20CrMnTi under different laser shock parameters were then simulated and analyzed. Based on the mechanical response of 20CrMnTi, the optimal parameters for single-point shocking via LSP were determined to be a shock energy of 5 J, a laser pulse width of 20 ns, and an impact number of 5. Lastly, a simulation of multi-point laser shock was conducted using the optimal parameters, and the residual compressive stress values of multi-point impacts were found to be similar to those of single-point impacts under the same process conditions.

MATERIALS (2023)

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Effects of building direction and loading mode on the high cycle fatigue strength of the laser powder bed fusion 316L

Xiaoyu Liang et al.

Summary: The study investigates the HCF performance of steel 316L fabricated by LPBF process. Bending and torsional fatigue test specimens built in different orientations were prepared and tested. Stress-relieving heat treatment was carried out to reduce residual stresses. The fatigue strengths varied under different loading conditions and building directions, with bending being more defect-sensitive than torsion. Fractographical analyses revealed the fatigue failure mechanisms, and microstructural features competed with inherent defects to affect fatigue performance.

INTERNATIONAL JOURNAL OF FATIGUE (2023)

Article Chemistry, Physical

Laser powder-bed fusion of a high entropy alloy with outstanding intrinsic mechanical properties

Navid Sohrabi et al.

Summary: In recent years, laser powder-bed fusion (LPBF) of high entropy alloys (HEAs) has attracted considerable attention. We investigated the microstructure and mechanical properties of a HEA (PdPtRhIrCuNi) fabricated by LPBF. This alloy shows potential applications in luxury industries and medical technologies. The microstructure consists of two coherent FCC phases behaving as a single-phase structure, with strong element segregation. The fine microstructure is attributed to the high cooling rate of the LPBF process. Two cracking mechanisms, solidification and liquation, were identified, and cracks propagate through grain boundaries and inter-dendritic regions. Despite the presence of micro-cracking, the mechanical properties in compression, bending, and wear resistance are excellent. The application of a new hybrid technique, 3D laser shock peening (3D LSP), effectively reduces crack density.

JOURNAL OF ALLOYS AND COMPOUNDS (2023)

Review Engineering, Industrial

On-line evaluation and monitoring technology for material surface integrity in laser shock peening-A review

Rui Qin et al.

Summary: Laser shock peening (LSP) is a surface plasticity strengthening technique that enhances the mechanical properties of metallic materials by introducing residual compressive stresses and improving the microstructure on the material surface. The development of online monitoring technology can ensure stable and efficient production processes and further advance the technology in high-quality and high-efficiency production areas.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2023)

Article Materials Science, Coatings & Films

Superior effects of hybrid laser shock peening and ultrasonic nanocrystalline surface modification on fatigue behavior of additive manufactured AlSi10Mg

Erfan Maleki et al.

Summary: The surface texture of metallic parts produced by laser powder bed fusion (L-PBF) significantly affects their mechanical properties, particularly fatigue behavior. Post-processing methods, such as laser shock peening (LSP) and ultrasonic nanocrystalline surface modification (UNSM), can effectively improve the mechanical performance of these materials. By conducting a range of experiments, it was found that the hybrid LSP + UNSM process resulted in a significant improvement in mechanical properties and fatigue behavior due to sub-surface pores closure, increased surface hardness, induced surface compressive residual stresses, and reduced surface roughness. The fatigue life was improved by up to 75, 56, and 35-fold compared to the as-built state after applying LSP + UNSM, UNSM, and LSP treatments, respectively.

SURFACE & COATINGS TECHNOLOGY (2023)

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Laser shock peening: a promising tool for enhancing the aeroengine materials' surface properties

K. Praveenkumar et al.

Summary: Laser shock peening (LSP) is an effective surface modification technique to enhance the properties of metallic materials. This paper reviews recent research on the application of LSP in improving surface characteristics and addressing service challenges in aeroengine materials. It also provides an overview of LSP and its controlling parameters. Challenges and future aspects for improving LSP application and commercialization in the aeroengine industry are discussed based on the authors' experience and published literature.

SURFACE ENGINEERING (2023)

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Progressive developments, challenges and future trends in laser shock peening of metallic materials and alloys: A comprehensive review

Weiwei Deng et al.

Summary: Grain refinement and arrangement is an effective strategy to enhance the properties of metallic components, and laser shock peening (LSP) is a promising surface deformation method. However, there is a lack of comprehensive understanding of the microstructural evolution and mechanical properties induced by LSP in the past two decades. This study summarizes the unique microstructural features and grain refinement mechanisms induced by LSP in three crystal structures, and introduces emerging hybrid LSP technologies and their industrial applications. The challenges and future trends are also discussed.

INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE (2023)

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A study on the effects of laser shock peening on the microstructure and substructure of Ti-6Al-4V manufactured by Selective Laser Melting

J. R. O. Leo et al.

Summary: The microstructure and deformation properties of Ti-6Al-4V fabricated by powder-bed fusion using different laser scanning strategies were studied. The microstructure in each condition was examined, and post-manufacture residual stresses were determined. The results showed a correlation between the residual stresses and the observed substructures, and suggested that the peening process can improve the mechanical properties and usability of the additively manufactured Ti-6Al-4V.

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Investigating the effect of laser shock peening on the wear behaviour of selective laser melted 316L stainless steel

K. Hareharen et al.

Summary: Selective Laser Melting (SLM) is an emerging additive manufacturing technology that allows highly customized metallic parts. However, the poor tribological performance of stainless steel 316L in the as-printed condition limits its applications. This study applies laser shock peening (LSP), a surface modification technique, to SLM-made SS 316L to improve its micro-structure, mechanical properties, and wear behavior. Results show that LSP promotes micro-level grain refinement and compressive residual stresses, resulting in increased micro-hardness and enhanced wear resistance.

OPTICS AND LASER TECHNOLOGY (2023)

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A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

Nabin Bastola et al.

Summary: Metal additive manufacturing can produce complex parts using functional metals, but residual stress remains a major concern due to the involvement of thermal energy. This study aims to comprehensively review and analyze different aspects of residual stress, including its causes and mechanisms, measurement techniques, influencing factors, effects on part quality and performance, and ways to minimize or overcome it.

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Effect of laser shock peening on microstructure and mechanical properties of TiC strengthened inconel 625 alloy processed by selective laser melting

Lan Chen et al.

Summary: In this study, a bulk nano-TiC particle reinforced Inconel 625 alloy was manufactured using selective laser melting, and the effect of post treatment on the microstructural evolution and mechanical properties of the alloy was investigated. The results showed that heat treatment and laser shock peening improved the performance of the alloy, generating high-density dislocations and nanoscale grains.

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Fatigue life extension of additively manufactured Nickel-base 718 alloy by nanostructured surface

Ruslan M. Karimbaev et al.

Summary: The beneficial effect of ultrasonic nanocrystal surface modification (UNSM) treatment on the mechanical properties and fatigue performance of Nickel-base 718 alloy fabricated by laser directed energy deposition (LDED) process was investigated in this study. The treatment demonstrated a significant enhancement in fatigue performance by introducing high compressive residual stress (CRS) and generating a nanostructured surface layer. Additionally, it was found that surface roughness decreased and hardness increased after the treatment.

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Study on very high cycle fatigue properties of forged TC4 titanium alloy treated by laser shock peening under three-point bending

Bohan Wang et al.

Summary: This study investigated TC4 titanium alloy with different laser shock peening treatments using three-point bending ultrasonic fatigue tests. The results showed that the HCF properties of the alloy improved, while the VHCF properties deteriorated after a certain level of laser shock peening treatment. Further analysis revealed that the shift of the crack origin zone and the combined effect of residual compressive stress and surface nanocrystals played important roles in fatigue strengthening, whereas excessive grain refinement and subsurface failure mechanism weakened the fatigue properties.

INTERNATIONAL JOURNAL OF FATIGUE (2022)

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On the effects of laser shock peening on fatigue behavior of V-notched AlSi10Mg manufactured by laser powder bed fusion

Erfan Maleki et al.

Summary: Post-processing methods, such as T6 thermal treatment, laser shock peening, and electrochemical polishing, were investigated for their effects on the properties of laser powder bed fusion materials. It was found that laser shock peening has the potential to close sub-surface pores and, when combined with heat treatment and polishing, significantly improve the fatigue life of the materials.

INTERNATIONAL JOURNAL OF FATIGUE (2022)

Article Chemistry, Physical

Achieving high strength and ductility in selective laser melting Ti-6Al-4V alloy by laser shock peening

Jiming Lv et al.

Summary: This research investigated the influences of laser shock peening (LSP) on the residual stress state, microstructures, and mechanical properties of Ti-6Al-4V alloy fabricated by selective laser melting (SLM). The results showed that LSP treatment adjusted the residual stress from tensile to compressive state and promoted the formation of high-density dislocations and parallel nano mechanical twins (nano-MTs) in the coarse lamellar alpha' structures, resulting in grain refinement. The ultimate tensile strength and elongation of the SLMed Ti-6Al-4V alloy increased by approximately 14.3% and 18.3% after LSP treatment, respectively. The study revealed that the combination of high levels of compressive residual stress and grain refinement achieved by LSP contributed to the enhancement of both strength and ductility in the alloy.

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The effect of laser shock peening on surface integrity and high and very high cycle fatigue properties of 2024-T351 aluminum alloy

Zhi Qin et al.

Summary: This study investigates the impact of laser shock peening (LSP) on surface integrity, high cycle fatigue (HCF), and very high cycle fatigue (VHCF) properties of 2024-T351 aluminum alloy. The results show that LSP treatment increases surface roughness and microhardness, refines subgrain sizes, and introduces high-level compressive residual stresses. The fatigue life of the specimens is reduced, with a more significant effect at higher laser pulse energy.

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Fatigue life enhancement of additive manufactured 316l stainless steel by LSP using a DPSS laser system

Sanin Zulic et al.

Summary: This study investigates the fatigue life behavior of additively manufactured stainless steel 316L in a laser shock peening process, and finds that LSP operations can significantly improve residual stresses and fatigue life.

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A comprehensive review of fatigue behavior of laser shock peened metallic materials

Xiushuo Zhang et al.

Summary: Laser shock peening (LSP) is widely used in the manufacturing industry to improve the mechanical performance of metallic components by introducing compressive residual stress and finer grain. Proper design of processing parameters can greatly enhance fatigue performance. Studies have shown that residual stress and microstructure play crucial roles in fatigue improvement and failure mechanisms of peened metallic materials.

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Defect tolerant fatigue assessment of AM materials: Size effect and probabilistic prospects

Xiaopeng Niu et al.

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INTERNATIONAL JOURNAL OF FATIGUE (2022)

Article Nanoscience & Nanotechnology

Effect of laser shock peening on tensile properties and microstructure of selective laser melted 316L stainless steel with different build directions

W. W. Deng et al.

Summary: The effects of build direction and laser shock peening on the properties and microstructure of 316L stainless steel were investigated. The results showed that the strength and ductility of the stainless steel varied under different build angles and LSP treatments, with the sample fabricated at a 90-degree build angle and subjected to LSP having the best combination of strength and ductility.

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Post-processing of selective laser melting manufactured SS-304L by laser shock peening

Sunil Pathak et al.

Summary: This study investigates the post-processing of additively manufactured stainless steel (SS) 304 L samples through laser shock peening (LSP). The results show significant improvements in compressive residual stresses and surface morphology. These findings contribute to a better understanding of the LSP mechanism in the post-processing of AM parts.

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The effects of laser peening treatment on the very high cycle fatigue properties for AA2024-T351 alloy using a crystal plasticity framework

Bin Li et al.

Summary: The effects of laser shot peening on VHCF properties of AA2024-T351 alloy were investigated. Experimental results showed that the fatigue life decreased after laser peening with relatively high pulse energy. Observation of the fatigue fracture revealed obvious facets and refined grains on the shot peening surface, with an aspect ratio larger than that of the matrix material. By using a modified CP model, it was found that laser shot peening had a beneficial effect on fatigue properties considering grain refinement only, but had a detrimental effect when considering the combined influences of grain refinement and changing aspect ratio.

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The role of annealing heat treatment in high-temperature oxidation resistance of laser powder bed fused Ti6Al4V alloy subjected to massive laser shock peening treatment

Zhao Wang et al.

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Inkyu Yeo et al.

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