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<p>This study compares ordinary surface rolling (OSR), ultrasonic surface rolling (USR), and cavitation ultrasonic surface rolling (CUSR) on 7075 aluminum alloy to investigate the evolution of surface residual stress and microstructure. The results indicate that residual stress increases with static pressure and exhibits a trend of initial increase followed by a decrease as the rolling depth increases. Notably, CUSR yields the highest compressive residual stress (CRS), which surpasses that of USR and OSR by 6.6% and 27.1%, respectively. USR is more effective than OSR in promoting grain refinement in the surface layer. The introduction of the cavitation effect further enhances grain refinement, leading to a denser and more uniform microstructure and an increased thickness of the deformed layer. XRD analysis reveals no phase transformation after the three rolling methods but shows changes in grain orientation and grain boundary spacing. The finest grains are observed after CUSR, and the minimal grain size is 40.42&#xa0;nm in CUSR, which is 12.6% and 19.3% refined compared with the grains in USR and OSR, respectively. CUSR is an effective surface modification technique, expected to further improve the service performance of metal materials.</p>

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Residual Stress and Microstructure Evolution of 7075 Aluminum Induced by Ultrasonic Surface Rolling Coupled with Cavitation

  • 期刊论文

  • 发表日期：

    2025年3月10日

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  • Junhua Li,
  • Jianxin Zheng,
  • Liuyin Jia,
  • Hongbo Li

摘要

This study compares ordinary surface rolling (OSR), ultrasonic surface rolling (USR), and cavitation ultrasonic surface rolling (CUSR) on 7075 aluminum alloy to investigate the evolution of surface residual stress and microstructure. The results indicate that residual stress increases with static pressure and exhibits a trend of initial increase followed by a decrease as the rolling depth increases. Notably, CUSR yields the highest compressive residual stress (CRS), which surpasses that of USR and OSR by 6.6% and 27.1%, respectively. USR is more effective than OSR in promoting grain refinement in the surface layer. The introduction of the cavitation effect further enhances grain refinement, leading to a denser and more uniform microstructure and an increased thickness of the deformed layer. XRD analysis reveals no phase transformation after the three rolling methods but shows changes in grain orientation and grain boundary spacing. The finest grains are observed after CUSR, and the minimal grain size is 40.42 nm in CUSR, which is 12.6% and 19.3% refined compared with the grains in USR and OSR, respectively. CUSR is an effective surface modification technique, expected to further improve the service performance of metal materials.