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<p>The 7075-T6 aluminum alloy is extensively utilized in structural components, such as bolts, rivets, and sheets, across the civil, mechanical, and aerospace industries. However, these components are highly susceptible to fatigue fracture when subjected to prolonged, low-amplitude vibrational loading. While shot peening is a widely adopted surface enhancement technique that significantly influences fatigue performance, its complex mechanisms require precise modeling. This study develops an integrated framework combining crystal plasticity finite element (CPFE) simulations with experimental validation to predict and verify the high cycle fatigue (HCF) and very high cycle fatigue (VHCF) life of shot-peened 7075-T6 alloy. The proposed model explicitly incorporates two critical shot peening effects: surface roughness, which is parametrically coupled with the subsurface microstructure, and the compressive residual stress (CRS) field, introduced via a quasi-thermal eigenstrain method. Furthermore, an energy-based fatigue criterion, refined through CPFE results, was employed to characterize the fatigue behavior across different peening intensities. Our findings demonstrate that the model accurately captures experimentally observed fatigue behaviors by accounting for the synergistic effects of surface topography and CRS. Specifically, at a peening intensity of 0.10 mmA, the CRS field predominantly enhances fatigue life; conversely, at 0.15 mmA, the detrimental impact of surface roughness becomes the governing factor. This research not only establishes a robust methodology for life prediction in both untreated and shot-peened specimens but also provides quantitative insights for optimizing the fatigue resistance of 7075-T6 alloy within the HCF and VHCF regimes.</p>

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A crystal plasticity framework for predicting gigacycle fatigue life in shot-peened 7075-T6 aluminium alloy

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Hongchang Ma,
  • Bin Li,
  • Hanzhe Chen,
  • Hongqian Xue

摘要

The 7075-T6 aluminum alloy is extensively utilized in structural components, such as bolts, rivets, and sheets, across the civil, mechanical, and aerospace industries. However, these components are highly susceptible to fatigue fracture when subjected to prolonged, low-amplitude vibrational loading. While shot peening is a widely adopted surface enhancement technique that significantly influences fatigue performance, its complex mechanisms require precise modeling. This study develops an integrated framework combining crystal plasticity finite element (CPFE) simulations with experimental validation to predict and verify the high cycle fatigue (HCF) and very high cycle fatigue (VHCF) life of shot-peened 7075-T6 alloy. The proposed model explicitly incorporates two critical shot peening effects: surface roughness, which is parametrically coupled with the subsurface microstructure, and the compressive residual stress (CRS) field, introduced via a quasi-thermal eigenstrain method. Furthermore, an energy-based fatigue criterion, refined through CPFE results, was employed to characterize the fatigue behavior across different peening intensities. Our findings demonstrate that the model accurately captures experimentally observed fatigue behaviors by accounting for the synergistic effects of surface topography and CRS. Specifically, at a peening intensity of 0.10 mmA, the CRS field predominantly enhances fatigue life; conversely, at 0.15 mmA, the detrimental impact of surface roughness becomes the governing factor. This research not only establishes a robust methodology for life prediction in both untreated and shot-peened specimens but also provides quantitative insights for optimizing the fatigue resistance of 7075-T6 alloy within the HCF and VHCF regimes.