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<p>This study examines the effects of severe shot peening (SSP) on the microstructural, mechanical, and fatigue properties of A356 aluminum alloy, commonly used in automotive and aerospace applications. The alloy was cast, machined, and subjected to conventional shot peening (CSP) and SSP at Almen intensities of 8N, 11N, and 18N. Surface roughness increased with SSP due to intense plastic deformation, though higher intensities resulted in a more homogeneous surface. Microstructural analysis <i>via</i> SEM and XRD revealed grain refinement, increased dislocation density, and redistribution of eutectic Si phases, particularly in subsurface regions. Residual stress analysis confirmed that SSP-induced deep compressive stresses, with 18N achieving the highest magnitude. Mechanical testing showed that SSP (18N) increased hardness by 2.38 times compared to the untreated alloy. Fatigue tests demonstrated a significant improvement in fatigue strength, with SSP doubling the fatigue limit relative to the untreated sample. The enhancements were attributed to compressive residual stress, strain hardening, and refined microstructure. However, excessive peening intensity (18N) led to surface microcracks, highlighting the need for careful parameter optimization. In addition, CSP and SSP were found to significantly modify the existing casting-related defects, which played a critical role in enhancing the fatigue performance of the A356 alloy. Overall, SSP is shown to be a cost-effective surface treatment for A356 aluminum alloy, providing substantial improvements in mechanical properties and fatigue performance. These findings offer valuable insights for optimizing SSP parameters in industrial applications requiring high durability and strength.</p>

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Improving Fatigue Strength of A356 Aluminum Alloy Through Severe Shot Peening: A Microstructural and Mechanical Study

  • 期刊论文

  • 发表日期：

    2025年7月21日

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  • Simge Gencalp Irizalp,
  • Burçak Kardelen Köroğlu,
  • İsa Yiğit,
  • Cansu Apaydin

摘要

This study examines the effects of severe shot peening (SSP) on the microstructural, mechanical, and fatigue properties of A356 aluminum alloy, commonly used in automotive and aerospace applications. The alloy was cast, machined, and subjected to conventional shot peening (CSP) and SSP at Almen intensities of 8N, 11N, and 18N. Surface roughness increased with SSP due to intense plastic deformation, though higher intensities resulted in a more homogeneous surface. Microstructural analysis via SEM and XRD revealed grain refinement, increased dislocation density, and redistribution of eutectic Si phases, particularly in subsurface regions. Residual stress analysis confirmed that SSP-induced deep compressive stresses, with 18N achieving the highest magnitude. Mechanical testing showed that SSP (18N) increased hardness by 2.38 times compared to the untreated alloy. Fatigue tests demonstrated a significant improvement in fatigue strength, with SSP doubling the fatigue limit relative to the untreated sample. The enhancements were attributed to compressive residual stress, strain hardening, and refined microstructure. However, excessive peening intensity (18N) led to surface microcracks, highlighting the need for careful parameter optimization. In addition, CSP and SSP were found to significantly modify the existing casting-related defects, which played a critical role in enhancing the fatigue performance of the A356 alloy. Overall, SSP is shown to be a cost-effective surface treatment for A356 aluminum alloy, providing substantial improvements in mechanical properties and fatigue performance. These findings offer valuable insights for optimizing SSP parameters in industrial applications requiring high durability and strength.