Induction of through-thickness compressive residual stress fields in thin Al2024-T351 plates by laser shock processing

Abstract

Purpose – With the aid of the calculational system developed by the authors, the analysis of the problem of laser shock processing (LSP) treatment for induction of residual stress (RS) fields for fatigue life enhancement in relatively thin sheets in a way compatible with reduced overall workpiece deformation due to spring-back self-equilibration has been envisaged. Numerical results directly tested against experimental results have been obtained confirming the critical influence of the laser energy and irradiation geometry parameters. The paper aims to discuss these issues. Design/methodology/approach – Plane rectangular specimens (160 mm×100 mm×2 mm) of Al-cladded (∼80 μm) Al2024-T351 were considered both for LSP experimental treatment and for corresponding numerical simulation. The test piece is fixed on a holder and is driven along X and Y directions by means of an anthropomorphic robot. The predefined pulse overlapping strategy is used for the irradiation of extended areas of material. From the geometrical point of view, a full 3D configuration for the real geometry and for the sequential overlapping strategy of pulses has been considered. The FEM elements used for the simulation are an eight-node brick reduced integration with hourglass control in the treated area, namely C3D8RT, and a six-node trainer prism in the rest of the geometry, where there is no applied load, namely C3D6T, that ease meshing complex partitions. The element size in the nearest of the treated surface is 100×100×25 µm, being the maximum element size which allows to maintain calculation convergence. Findings – Numerical results directly tested against experimental results have been obtained confirming: first, the critical influence of the laser energy and irradiation geometry parameters on the possible thin sheets deformation, both at local and global scales. Second, the possibility of finding LSP treatment parameter regimes that, maintaining the requirements relative to in-depth RSs fields, are able to reduce the relative importance of sheet deformation. Third, the possibility of finding LSP treatment parameter regimes able to provide through-thickness compressive RSs fields at levels compatible with an effective fatigue life enhancement. Fourth, the possibility of improving this through-thickness compressive RSs fields by double-side treatments. Fifth, the capability of the experimental LSP treatment system at the authors site (CLUPM) of practically achieve the referred through-thickness compressive RSs fields in excellent agreement with the predictive assessment obtained by the used numerical code (SHOCKLAS®). Practical implications – The referred results provide a firm basis for the design of LSP treatments able to confer a broad range of RSs fields to thin components aiming the extension of their fatigue life, an enormously relevant field in which the authors are currently working. Originality/value – The LSP treatment of relatively thin specimens brings, as an additional consequence, the possible bending in a process of laser shock forming. This effect poses a new class of problems regarding the attainment of specified RS’s depth profiles in the mentioned type of sheets, and, what can be more critical, an overall deformation of the treated component. The analysis of the problem of LSP treatment for induction of tentatively through-thickness RS’s fields for fatigue life enhancement in relatively thin sheets in a way compatible with reduced overall workpiece deformation due to spring-back self-equilibration is envisaged in this paper for the first time to the authors knowledge. The coupled theoretical-experimental predictive approach developed by the authors has been applied to the specification of LSP treatments for achievement of RS’s fields tentatively able to retard crack propagation on normalized specimens.