Surface severe plastic deformation of AISI 304 via conventional shotpeening, severe shot peening and...

8/17/2019 Surface severe plastic deformation of AISI 304 via conventional shotpeening, severe shot peening and repeening

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Applied Surface Science 351 (2015) 289–295

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Applied Surface Science

j ou rna l ho mep age : www.e l sev i e r. com/ loca t e / apsusc

Surface severe plastic deformation of AISI 304 via conventional shotpeening, severe shot peening and repeening

Okan Unal a , ∗ , Remzi Varol ba Mechanical Engineering Department, Bartın University, Bartın 74100, Turkeyb Mechanical Engineering Department, Suleyman Demirel University, Isparta 32200, Turkey

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Article history:Received 1 February 2015Received in revised form 14 May 2015Accepted 16 May 2015Available online 23 May 2015

Keywords:Severe shot peeningRepeeningSMATFWHMSurface roughnessNanocrystalline layer

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Air blast conventional shot peening (CSP), severe shot peening (SSP) and repeening (RP) as a severe plasticdeformation applications on AISI 304 austenitic stainless steel is addressed. Shot peened specimens areinvestigated based on optical, FESEM and digital microscope. The investigations present the austenitetransformation to metastable martensite via mechanical twinning due to plastic deformation with highstrain rates. It is found that SSP induces thicker nanograin layer with compared to CSP. In XRD studies,the austenite peaks broaden by means of severe shot peening and FWHM increase reveals the grain sizereduction below 25 nm regimes on the surface. In EDAX line analysis of CSP specimen, carbon contentincrease has been detected from deformed layer through the nanocrystalline layer then the contentreduces. The carbon segregation takes place due to the energy level distinction between dislocationsand Fe C bonds. 3d contour digital microscope studies and roughness investigations reveal that SSP hasdeleterious side effect on the surface roughness and surface atness. However, RP is an effective way toreduce the surface roughness to reasonable values.

© 2015 Elsevier B.V. All rights reserved.

1. Introduction

Nanostructure formation on surface or bulk material havereceived great attention and remarkable importance due to havingsuperior mechanical, physical and chemical properties [1] . Surfacesevere plastic deformation methods bring ordinary metallic mate-rials innovations by means of new and effective features [2] . Themethods alsomake contributions on hardness,corrosion and tribo-logical properties. These methods expose plastic deformation withhigh strain rates to the materials [3] . The dislocation and twinningactivities leads to subdivision of grains. Grain size reduction andthe increase of grain boundary proportion besides occurrence of nanograinedlayer contributes distinctproperties fromcoarse graininteriors [4] .

Shot peening effect has known on the fatigue propertiesby means of gaining ability to introduce compressive residualstress. Compressive residual stress through the interior retardsthe fatigue failure of dynamically loaded machine parts [5–10] .Recently, shot peening with increased application parameters

∗ Corresponding author. Tel.: +90 378 223 53 65;fax: +90 378 223 53 58.E-mail addresses: [email protected] , [email protected]

(O. Unal).

(Almen intensity, shot diameter and air pressure) has been per-formed as a surface severe plastic deformation method. Shotpeening with increased parameters is called as “severe shotpeening”. SSP has been applied for similar objectives with SSPDmethods [11] . This method also creates nanograined layer onand just below the surface and exposes material deeper com-pressive residual stress [12] . Also, SSP has benecial effect oncorrosion resistance with compared to conventional shot peening[13] . However, it has a critical disadvantage for surface roughness.Therefore,new applicationssuchas repeeningand multisteppeen-ing have been applied for surface roughness reduction [14,15] .For mechanical properties, such as fatigue, fretting fatigue, cor-rosion, stress corrosion, wear, friction and surface roughness,detail investigations should be performed for new type of shotpeening processes due to primary importance of surface charac-teristics.

Inthis study,AISI304 austenitic stainless steel has been selectedfor the investigations. The material exhibits remarkable corrosionandheat resistance. It is used for biomedical applicationsand it hasgreatability to plastic deformation. Different types of shotpeening,CSP (A12–14), SSP (A28–30, A34–36) and RP (N6–8 after A34–36)have been performed and the comparison of the new shot peeningtreatments have been conducted within the context of microstruc-ture, surface roughness and microhardness.

http://dx.doi.org/10.1016/j.apsusc.2015.05.0930169-4332/© 2015 Elsevier B.V. All rightsreserved.

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Table 1Mechanical properties of AISI 304 austenitic stainless steel.

0.2% Yield strength (MPa) Tensile strength (MPa) Elongation % Reduction of area % Hardness HB

541 748 39.0 70.0 222

2. Experimental methods

2.1. Material

AISI 304 austenitic stainless steel specimens (25 mm and5mm thickness), having a chemical composition of (in wt.%) C:0.041, Mn: 1.680, Si: 0.390, S: 0.024, P: 0.034, Cr: 18.250, Ni: 8.040,Cu:0.56, Mo: 0.26,Co: 0.17, Fe:balance;wereused.The mechanicalproperties of the AISI 304 is given in Table 1 .

2.2. Shot peening

The specimenshavebeen exposed to severe plastic deformationvia CSP, SSP and RP. The SSP specimens were compared with CSPones within the context of microstructure and mechanical proper-ties. RP has been performed after SSP in order to improve surfacecharacteristics. SSP has been provided by means of raising air pres-sureand shotdiameter, particularly.Almenintensity is determinedrstly shot peening of Almen strips (AISI 1070 high carbon steel).Then, Almen intensity is evaluated by measuring the arc height(deection) of the Almen strips. Fig. 1 and Table 2 shows the shotpeened Almen strips and the parameters that provides convenientpeening conditions, respectively.

Allshotpeened specimenswere cut from the cross sections thengrounded from 240 to 1200 grade emery papers and mechanicallypolished with 6, 3, 1 and 0.25 m diamond pastes. The specimenswere etched by immersing 100 ml water, 100 ml hydrochloric acidand 10ml nitric acid solution for 180–210s.

2.3. Surface roughness

Surface characteristics vary rigorously after the application of shot peening so, the mechanical properties have been inuenced.Thus,surfaceroughness measurementsweredetermined viaa con-tactstylus prolometer by Mitutoyo Surface Roughness Tester. Thetests were performed on ve different location to determine Ra , Rqand R z of the specimens.Huvitz Digital Microscope HDS-5800 wereusedfor distinguishing theall shotpeeningtreatments effect on thesurface.

2.4. Mechanical and microstructure characterization

AISI 304 austenitic stainless steel specimen microstructurealteration after SSP, CSP and RP were analysed by meansof optical microscopy (OM) and eld emission scanning elec-tron microscopy (FESEM). Nikon Eclipse MA100 is used for

optical microscopy (OM) and Carl Zeiss Gemini Sigma is usedfor FESEM analysis. The phase, FWHM and crystallite size anal-

ysis were determined on the surface via Rigaku SmartLabdiffractometer using Cu K radiation (scanning speed: 2 ◦ /min;voltage: 40kV, scanning angle: 20 ◦ –90 ◦ and current: 30mA).FWHM and crystallite size analysis of the (111) and ’(110) and were performed by means of pseudo-Voigt func-tion and Scherrer equation [16] . The overlapped peaks havebeen investigated in two steps. Multiple peak t analysis andprole tting steps have been applied consecutively. The instru-mental broadening had been evaluated by using a standardsilicon sample and subtracted from (111) and ’ (110) peaksFWHM. Qness GmbH Q10 microhardness tester is used fordetermining the microhardness alteration from shot peenedsurface through the interior with a load of 5gf with a duration of 10s.

3. Results and discussion

3.1. Microstructure analysis

CSP, SSP and RP specimen images are presented together inFig. 2 . Shot peening induces high strain rate on the AISI 304 surfaceand transforms the austenitic structure to metastable martensitephase.Thegurealsoshows that SSPleads toformation ofdeforma-tion twins. In CSP specimen ( Fig. 1a), the mechanical deformationeffect is too low to observe and only local, limited strain inducedmartensite formation can be observed. However, SSP is capable of forming the strain induced martensite layer and creates this layerup to 200 m ( Fig. 2b and c). SSP condition increase up to A34–36Almen intensity spreads out the mechanical twins along the sur-face( Fig.2c). AlthoughSMAT parameters (shot diameter,treatmentduration)arehigher than theair blastSSP, SSPmanagesto inuencethematerialswithinthe contextof layerthickness comparable withSMAT [13,16] . Repeeningsupports homogenizationof thedeforma-tion induced martensite along the surface and also throughout theinterior up to approximately 200 m ( Fig. 2d).

In optical micrographs of the CSP, SSP and RP specimen, onlythe mechanically deformed layer formation can be observed. How-ever, nanocrystalline layer can be seen besides mechanical twindeformed layer in FESEM analysis ( Fig. 3). The gure shows thatthe deformation rate increase leads to nanocrystalline thicknessincrease. The nanolayer thickness stays 8 m for the CSP speci-men. However, SSP increases the thickness up to 12 mand22 mfor A28–30 and A34–36 Almen intensity, respectively. In Fig. 4,FESEM image assessments depict mechanical twinning is formed

Fig. 1. Almen strips (A–N) and their parameters of theconventional (A12–14), severeshot peening (A28–30; A34–36) and repeening (N6–8).


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Table 2Arc height and shot peening parameters for each pre-determined Almen intensity.

Almen intensity Shot size Coverage (%) Duration (s) Air pressure (psi) Arc height (mm)

A12–14 (CSP) S230 200 10 30 0.14A28–30 (SSP) S230 200 15 60 0.29A34–36 (SSP) S230 200 20 70 0.34N6–8 (RP) S230 200 2 20 0.8

Fig. 2. Optical microscope imagesof shot peenedspecimens (a) CSP (A12–14) (b) SSP(A28–30) (c)SSP (A34–36) (d) RP (N6–8 after A34–36).

Fig. 3. FESEM images and thicknessof thenanograined layer of shot peenedspecimens (a) CSP(A12–14) (b) SSP(A28–30) (c) SSP(A34–36).


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Fig. 4. FESEM (1000 × ) imagesof mechanical twins and interactionsof SSPspecimens (a) A28–30 (b) A34–36 (c)higher magnication(4000 × ) of a (d)higher magnication(4000 × ) ofb.

Fig. 5. FESEM image and line EDAX analysis of CSP (A12–14) specimen.

in highly deformed regions of SSP specimen. Mechanical twinning,twin interactions and these structures can be identied at highermagnications in detail ( Fig. 4c and d).

Fig. 5 shows FESEM images and EDAX line analysis of CSP(A12–14) specimen. The FESEM images and EDAX analysis havebeen performed to distinguish deformed (ne grained layer),nanocrystalline structure and the transition range. The EDAX lineanalysis reveals that Fe, Ni, Cr, Mn and C exist as their expectedratios in the deformed layer. Upon transition range, all elementsexcept “C” begin to reduce. However, “C” content increases. Pass-ingof transition range towards thenanocrystallinelayer, theabruptreduction of Fe and Cr carries on, Ni and Mn vanish and“C” reachesto itsmaximumvalues at thebeginningof thenanocrystallinelayer.This layer promotes carbon diffusion (jump) from interior due toenergy leveldistinctionclose the transition range [17] . Thencarboncontent commences to reduce through the surface.

Nanograin formation and carbon segregation have been ana-lysed with 3d atom probe after the application of high pressure

torsion to pearlitic steel. Fe C bonds have been investigatedafter the application of critical shear stress level. Severe plasticdeformation leads to decompose Fe C structures and metastable

Fe C phases have been formed and carbon vacancies called“C-vacancies” have been created. However, the energy level of vacancies and dislocations formed in ferrite regions become morefavourable for C segregation [18] . The carbon segregation has beendetected through the dislocation cell boundaries [19] . XRD stud-ies show that there is no lattice parameter alteration of -Fephases. TheXRD results revealthatthe segregation takes place onlythrough the dislocation vacancies [20] .

3.2. XRD analysis

The XRD patterns of as received, CSP, SSP and RP treated AISI304 specimens are shown in Fig. 6 . As received specimen revealsthe austenite (111), (200) and (220) peaks. CSP leads to

formation austenite to martensite transformation, since ˛ (110)


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Table 3FWHM values and two theta of thespecimens for each shot peening conditions.

Specimen Peak 2-theta ( ◦ ) FWHM Peak 2-theta ( ◦ ) FWHM

As received γ (1 1 1) 43.78 0.477 ˛ (1 1 0) – –CSP (A12–14) γ (1 1 1) 43.99 0.690 ˛ (1 1 0) 44.917 1.121SSP (A28–30) γ (1 1 1) 44.03 3.680 ˛ (1 1 0) 44.973 4.878SSP (A34–36) γ (1 1 1) 44.22 3.937 ˛ (1 1 0) 45.010 4.361RP (N6–8) γ (1 1 1) 44.12 3.717 ˛ (1 1 0) 44.901 2.814

Fig. 6. TheXRD patterns of theas received and shot peenedspecimens.

and ˛ (21 1) metastable martensite phases become to exist. BothSSP and CSP applications set off the metastable martensite phases.However, the austenite and martensite phases exist together inthe shot peened specimen matrix. Although the severe plasticdeformation types are different, the transformations via SSP arequite similar with the SMAT and cold rolling processes [13,21] .

The plastic deformation mechanism of AISI304 austenitic stain-less steel is quite different from dislocation based mechanismssince mechanical twinning is the primary deformation system dueto having low stacking fault energy. Plastic deformation increasepromotes twin intersections and these intersections provide sub-grain austenite formation [22] . Crystallite size determination byXRD analysis carries out by means of FWHM analysis. Crystallitesize reduction below 100 nm can be evaluated viapeak broadeningafter SSP applications. The crystallite size on the surface reducesbelow 25nm after all severe shot peening processes. FWHM anal-ysis has been performed by using pseudo-Voigt function. For thepeaks γ (11 1) and ˛ (110) the FWHM values are obtained andthe evaluation is performed via Scherrer equation. SSP provides

Fig. 7. 3d contour proles of shot peened specimens(a) A12–14 (b) A28–30 (c)A34–36 (d) A34–36+ N6–8.


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Fig. 8. Surface roughnessproles of shot peenedspecimens (a)A12–14 (b) A28–30 (c) A34–36 (d) A34–36+ N6–8.

Fig. 9. Microhardness variations of theas received and shot peened specimens.

broadening of the peaks and raising the FWHM effectively ( Table 3 )[2,3] . In literature, althoughthe specimens which arenotexposedtoplastic deformation, the XRDpatternsshowweak martensite peaksdue to the machining or polishingeffects. The electrically polishingspecimen has only austenite peak, on the contrary mechanicallypolished specimen has both austenite and martensite peaks [23] .

However, in this study, we could not obtain any peak and also anyFWHM valuesfor ˛ on“as received”specimens so we onlypresents˛ informations for CSP, SSP (A28–30), SSP (A34–36)and RP (N6–8)specimens.

After the severe plastic deformation methods, also microstrainevaluations by using X-ray diffraction help to determine the inu-ence of the deformation process such as residual stress, FWHMandcrystallite size evaluations. Microstrain alterations particularlyafter shot peening have been investigated in most studies [24–26] .

3.3. Surface roughness analysis

Surface roughness has been inuenced by both mechanicaland thermal surface treatments. Shot peening can be assessed as

mechanical surface treatment and affects the surface roughness.

Shot peening plays a critical role on raising the surface roughness[27] . If the fatigue life of the metallic parts is taken into account,controlling the surface roughness will be benecial particularly forload carrying mechanical parts [28] . In that manner, CSP, SSP andRP applications should be analysed in detail by means of surfaceroughness. RP treatment has been decided to apply in order to

reduce the roughness values. Fig. 7 shows the 3d contour proleof the peened specimen via Huvitz Digital Microscope HDS-5800.Fig.7 a CSP (A12–14), Fig.7 b andc SSP(A28–30, A34–36)and Fig. 7dshow RP (N6–8) specimen surface.

According to the 3d contour proles, harmful effects can beseen on the surface after the application of SSP treatments. Surfacedeterioration stays minimum on the CSP specimen. RP treatmentreduces the roughness values and deteriorative pits and bumps.Fig. 8 presents the surface roughness proles of the shot peenedspecimens. Moreover, Table 4 reveals the surface roughness Ra , Rqand R z values of the CSP, SSP and RP specimens.

According to the roughness measurements ( Table 4 ) SSPincreases surface roughness abruptly. CSP leads to stay the valuein reasonable range. The study presents RP is an effective way to

reduce the roughness after SSP applications. Moreover, for further


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Table 4Thesurface roughnessvalues ( Ra , Rq , R z ) of the specimensafter conventional, severeshot peening and repeening.

AISI 304 Ra Rq R z

A12–14 1.841 2.278 9.759A28–30 2.990 3.599 14.483A34–36 2.832 3.442 14.292N6–8 (after A34–36) 2.327 2.83 11.327

investigations increasing of surface coverage and decreasing theshot diameter during RP treatment will help the reduction of sur-face roughness.

3.4. Microhardness measurements

Shot peening treatments expose plastic deformation to metallicmaterials through the interior. However, the deformation depthinuence of the CSP, SSP and RP treatments are quite different.Hardness measurements are performed by using Vickers indenterwith 5gf load and interior up to 200 m with 10 m intervals inorder to compare the treatments by means of microhardness vari-ations ( Fig. 9). The measurements reveal the plastic deformationeffect of each shot peening treatment. The SSP effect on hardeningof all the treated specimenshas been substantially released where-after 120 m. However, CSP hardening effect released whereafter40 m. SSP treatment raises the hardness up to 730 HV. Similarly,CSP treated specimen increases the surface hardness up to 650HV.High level of plastic deformation capability and strain hardeningrate of AISI 304 austenitic stainless steel can be attributed to thesimilar effect of CSP and SSP treatments.

4. Conclusions

CSP, SSP and RP expose high plastic deformation and increasesthe surface hardness on the AISI 304. CSP and SSP raises the sur-face roughness however RP shows an inverse effect. CSP, SSP andRP applications leads to mechanical twins and strain induced mar-tensite formation. The nanograinedlayer thicknesson thesurface isrelated with the plastic deformation rate of the shot peening treat-ments. CSP formsapproximately8 m nanograined layerhowever,SSP has the ability to reach the thickness of 22 m. FWHM evalu-ated (by pseudo-Voigt function) from peak broadening increasesviaonly SSP. The EDAX line analysis of CSP specimen shows carboncontent increase from the transition range through the nanocrys-talline layer and then tends to reduce. Severe plastic deformationinduces carbon segregation through the dislocations by separatingFe C bonds due to the energy level distinction.

Acknowledgment

This work was supported by Suleyman Demirel University Sci-entic Research Projects Coordinatorship (Grant no: 3705-D2-13).

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Surface severe plastic deformation of AISI 304 via conventional shotpeening, severe shot peening and...

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Transcript of Surface severe plastic deformation of AISI 304 via conventional shotpeening, severe shot peening and...