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<p>Selective Laser Melting (SLM)-fabricated Ti-6Al-4V alloys often contain defects such as porosity, high surface roughness, and tensile residual stresses, which limit their fatigue performance. This study investigates the effects of conventional (CSP, 11 N) and severe (SSP, 18 N) shot peening on the surface integrity and fatigue behavior of polished SLM specimens. Surface morphology, microstructure, x-ray diffraction (XRD) peak broadening, microhardness profiles, and tensile–tensile fatigue performance were examined. Both CSP and SSP enabled partial closure of surface-connected pores and refinement of α′ martensitic laths, increasing near-surface dislocation density. Surface microhardness increased by 17% after CSP and 40% after SSP, while the FWHM of the α′(101) peak increased by 122% and 137%, indicating enhanced lattice strain. The fatigue limit rose from 132&#xa0;MPa to 200&#xa0;MPa for both treatments, with SSP providing ~ 70% longer life at 230&#xa0;MPa. Overall, SSP demonstrated superior effectiveness in improving microstructure and fatigue resistance.</p> Graphical Abstract <p></p>

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Effects of Conventional and Severe Shot Peening on Surface Integrity and Fatigue Behavior of Selective Laser Melting-Fabricated Ti-6Al-4V Alloy

  • 期刊论文

  • 发表日期：

    2026年7月22日

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  • Simge Gencalp Irizalp,
  • Cansu Apaydin

摘要

Selective Laser Melting (SLM)-fabricated Ti-6Al-4V alloys often contain defects such as porosity, high surface roughness, and tensile residual stresses, which limit their fatigue performance. This study investigates the effects of conventional (CSP, 11 N) and severe (SSP, 18 N) shot peening on the surface integrity and fatigue behavior of polished SLM specimens. Surface morphology, microstructure, x-ray diffraction (XRD) peak broadening, microhardness profiles, and tensile–tensile fatigue performance were examined. Both CSP and SSP enabled partial closure of surface-connected pores and refinement of α′ martensitic laths, increasing near-surface dislocation density. Surface microhardness increased by 17% after CSP and 40% after SSP, while the FWHM of the α′(101) peak increased by 122% and 137%, indicating enhanced lattice strain. The fatigue limit rose from 132 MPa to 200 MPa for both treatments, with SSP providing ~ 70% longer life at 230 MPa. Overall, SSP demonstrated superior effectiveness in improving microstructure and fatigue resistance.

Graphical Abstract