Fatigue life improvements of the AISI 304 stainless stell ground surfaces by wire brushing

The surface and subsurface integrity of metallic ground components is usually characterized by an induced tensile residual stress, which has a detrimental effect on the fatigue life of these components. In particular, it tends to accelerate the initiation and growth of the fatigue cracks. In this investigation, to deliberately generate compressive residual stresses into the ground surfaces of the AISI 304 stainless steel (SS), wire brushing was applied. It was found that under the experimental conditions selected in this investigation, while the surface roughness was slightly improved by the brushing process, the surface residual stress shifted from a tensile stress (sigma(parallel to) = +450 MPa) to a compressive stress (sigma(parallel to) = -435 MPa). On the other hand, the work-hardened deformation layer was almost two times deeper after wire brushing. Concerning the fatigue life, an improvement of 26% in terms of endurance limit at 2 x 10(6) cycles was realized. Scanning electron microscope (SEM) observations of the fatigue fracture location and size were carried out to explain the fatigue life improvement. It was found that the enhancement of the fatigue strength could be correlated with the distribution and location of the fatigue fracture nucleation sites. Concerning the ground surfaces, it was seen that the fatigue cracks initiated at the bottom of the grinding grooves and were particularly long (150-200 mum). However, the fatigue cracks at the brushed surfaces were shorter (20-40 mum) and appeared to initiate sideways to the plowed material caused by the wire brushing. The results of the wire-brushed surface characterization have shown that significant advantages can be realized regarding surface integrity by the application of this low-cost process compared to shot peening.