Qualification and Deployment of Ultrasonic Shot Peening ... · Ultrasonic shot peening Ultrasonic...
Transcript of Qualification and Deployment of Ultrasonic Shot Peening ... · Ultrasonic shot peening Ultrasonic...
Qualification and Deployment of Ultrasonic Shot Peening System for Production and Repair in Automotive and Aerospace Industries
Hadrien VAUTHENYMaterial Science EngineerInternational Sales Engineer
SHTE, Västeras, SWEDENSeptember 22th, 2015
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Summary
1. Introduction : distorsion and residual stress
2. X-ray diffraction method for residual stress measur ement
3. Effect of Machining and heat treament on residual stre ss
4. The interest of Ultrasonic Shot Peening for distorsio n control
5. Conclusion
How to control and modify the residual stresses leading to distorsion effect on a critical engine part ?
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1. Introduction
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Introduction
SONATS is a private owned company located in Nantes, FRANCE since1991.
Dedicated to the Impact Surface Treatment , SONATS has developped a very wide range of Services and Equipements with a Laboratory and Manufacturing facilities :
_ Residual Stress Measurement (RSM) by X-Ray diffraction_ Ultrasonic Shot Peening Equipement_ Forming and Straightening Equipement_ Needle Peening Equipement
=> One target : Improve the mechanical properties and the fatigue life resistance of metalic parts and structures in an y industrialsector.
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Introduction
Rotating parts dedicated to Engine and Transmissionwith high dynamic and balancing properties in the Automotive andAerospace industries are subject to distorsion during and afterheat treatments.
Technical case :
Willing to implement a new design to a Turbo Wheelshaft, an Engine Manufacturer has been subject to a significantdecrease in life time of its Turbocharger. Despite a usualmechanical design and controlled heat treatment, distortion of theshaft is leading to miss-alignment and balancing issues causing aquick wear of the system.
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Introduction
• Turbo wheel and shaft for Automotive and Aeronautical Engines
Inconel wheel Steel shaft
Manufacturing processes :• Electron beam welding
between steel and Inconel• Hard turning• Grinding• Heat treatment• Etc.
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Introduction
When and where does appear distorsion ?
Distorsion may happen :• after heat treatment• after few hours of service � very hard to detect in production
05
1015202530354045
Y d
isto
rsio
n (µ
m)
X coordinate (n.c.)
Tolerance
3D scan
Inconel wheel Steel shaft
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Introduction
Hypothesis : Residual stresses still existing after heat treatment are released in service and lead to material deformation
How to measure and control residual stresses to reduce distorsion?
Inconel wheel Steel shaft
Distorsion at the weld
Distorsion on the shaft
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2. Residual stress measurement method
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Residual Stresses Measurement Method
X-ray diffraction stress analyzer :
StressTech XSTRESS 3000 G2R (Finland)
� High voltage generator
� Goniometer
� Sofware
• Superficial measurement, non destructive testing• In-depth measurement when combined with electrochemical polishing (destructive)• European standard NF EN 15305• On metals and ceramics : low alloy steel, stainless steel, Aluminum alloys, titanium
alloys, Nickel-base alloys, Inconel, copper, bra advanced lightweight material (metal matrix composite, superalloys, etc.) …
• Limits : very large grains, important crystallographic texture
C.E. Murray, I.C. Noyan, Applied and residual stress determination using X-ray diffraction, in: G. S. Schajer (Ed.), Practical Residual Stress Measurement Methods, John Wiley & Sons Ltd., Chichester, 2013, pp. 139-162
F. Lefebvre, et al., External reference samples for residual stress analysis by X-ray diffraction, Advanced Materials Research 996 (2014), pp 221-227
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X-rays
Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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Mask
Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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MaskElectrochemical polishing
10 V
Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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Depth measurement : profilometer
d
Form Talysurf Intra2, TaylorObson
Residual Stresses Measurement Method
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X-rays
Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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X-rays
Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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X-rays
Depth (µm)
Stress(MPa)
0
50
100
150
200
0-100-200-300 100
Residual Stresses Measurement Method
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Depth (µm)
Stress (MPa)
0
0 50 100 150 200 250 300
-100
-200
-300
-400
100
Residual Stresses Measurement Method
Superficialstress
Sub surface stress gradient
Affected depth(considering surface treatment or machining)
Core stress evaluation
Information on : www.sonats-et.com
R. Menig, et al., Depth profiles of macro residual stresses in thin shot peened steel plates determined by X-ray and neutron diffraction, Scripta Materialia 45(2001), pp 977-983
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3. Effect of heat treatment and machining on residual st ress
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Effect of heat treatment and machining
Measurement on the shaft : Effect of machining operations
-400
-300
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-100
0
100
200
0 200 400 600 800
Axia
l R
esi
du
al Str
ess
es
[MPa
]Hard turning
Grinding
Hard turning = tension
Grinding = compression
Stress relieved core material
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Effect of heat treatment and machining
Measurement on the shaft : Non-symetric distribution of axial residual stress around the circumference
-200
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-160
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-120
-100
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-60
-40
-20
00° 120° 240°
Axi
al r
esid
ual s
tres
s[M
pa]
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RSM results before and afterheat treatment
Effect of the heat treatmentCorrect Relaxation of machining-induced superficial stress on the steel shaft
-503
-219
-6 -10-68
165
290250
1963 49
14
-550
-450
-350
-250
-150
-50
50
150
250
350
Axi
al r
esid
uals
tres
s[M
Pa]
6 2
-7 -28
1052
1360
-15
17 15 19
-550
-450
-350
-250
-150
-50
50
150
250
350
10h, 520°C
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Measurement on the Inconel-to-steel weld• Cutting of the part• Rotation during XRD measurement• Measurement at the 2mm wide fusion zone
Effect of heat treatment and machining
weld
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150
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0° 120° 240°
Res
idua
l str
ess
[Mpa
]
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Effect of the heat treatmentOnly partial relief of residual stress at the Inconel-to-steel weld
10h, 520°C
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250
0° 120° 240°
Res
idua
l str
ess
[Mpa
]
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0° 120° 240°R
esid
ual s
tres
s[M
pa]
Effect of heat treatment and machining
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• XRD is able to characterize the residual stress state of the part
• Machining operations induce non-homogeneous superficial residualstress on the steel shaft
• Heat treatment (520°C) relieves machining-induced residu al stress
• Inconel-to-steel welding induces large and inhomogeneous residualstress at the weld zone
• In this particular case, Heat treatment (520°C) does not relievewelding residual stress
• Significant residual stress may be present in the part at the end of the standard manufacturing process
=> Need of an additional process to modify the residual stress distribution and avoid the distorsion phenomenon
Effect of heat treatment and machining
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4. Ultrasonic shot peening
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Ultrasonic shot peening
Ultrasonic Shot peening is a cold working process used to introduce a compressive residual stress layerand modify mechanical properties of metals.It entails impacting a surface with shot (round metallic, or ceramic particles) with force sufficient to createplastic deformation.
J. Badreddine, et al., Simulation du grenaillage ultrason pour des pièces à géométries complexes, CSMA 2013 (2013)
J. Badreddine, et al., CAD based simulation of ultrasonic shot peening process, International Design Conference , Dubrovnik, Croatia, 2013
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Ultrasonic Shot Peening will modify the part :
_ localy (specific and targeted areas)
_ with control (real time monitoring of the process) and perfect repeatability
_ introducing homogenous compressive stresses
_ monitoring the roughness (increase or decrease after treatment according to the media size)
_ Increasing resitance to fatigue and cycle loadings
Ultrasonic shot peening
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5. Conclusion
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Conclusion
Turbo wheel case shows :
• Industrial issue for a criticalengine part
• Identification of root causes in the manufacturing process
• Method of measurement of the residual stresses, main rootcause of distorsion in this case.
• Identification of the critical areas of the part
• Quantification and validation of the heat treatment effects
• Additionnal process and complementary solution for homogeneous stress distribution in the part
The USP process :
• Is an high potential method for part quality improvement
• Is used in the aerospacial industry since1990
• Today under depoyement in the automotive, energy, spatial, infrastructure industries
� www.sonats-et.com
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Contacts
SONATS 2, rue de la Fonderie – BP 4053844475 Carquefou Cedex, FRANCEDirect : +33 2.40.52.99.38Mobile : +33 [email protected]@[email protected]
www.sonats-et.fr
Exportreform TLO AB Järnvägsgatan 36, 131 54 NACKA, SWEDENTelefon: 08-556 953 00Fax: 08-644 6511E-post: [email protected]
France
Sweden