Laser Shock Processing of Metallic Alloys: Process Overview and Development of Advanced Applications through the Integrated Modelling-Processing-Testing Approach for the Robust Design of Treatments on High- Reliability Components.

Laser Shock Processing of Metallic Alloys:

Process Overview and Development of Advanced Applications

through the Integrated Modelling-Processing-Testing

Approach for the Robust Design of Treatments on

High-Reliability Components.

J.L. Ocaña, J.A. Porro, M. Díaz, A. García-Beltrán, I. Angulo, F. Cordovilla

UPM Laser Center. Polytechnical University of Madrid.

Ctra. Valencia, km. 7.3. 28031 Madrid. SPAIN

e-mail:

[email protected]

Convention Center Nagoya Nagoya (Japan), 1-5 October 2017

INTRODUCTION

§

Laser Shock Processing (LSP) is developed as a technique allowing the

effective induction of residual stresses fields in metallic materials allowing a

high degree of surface material protection against fatigue crack propagation,

abrasive wear, chemical corrosion and other failure conditions.

§

_{This makes the technique specially suitable and competitive with presently use}

techniques for the treatment of heavy duty components in the aeronautical,

nuclear and automotive industries.

§

_{However, the practical application of LSP treatments to real high reliability}

components is burdened by a

lack of physical understanding of material

transformation mechanisms and the subsequent process design capability

.

§

_{By means of an integrated Modelling-Processing-Testing approach, the authors}

have

progressed in the physical process understanding and gained process

design capability

assuring the desired components performance improvement

sought through the application of LSP treatments.

§

A brief summary description of such integrated approach is described together

with some examples of its application and a presentation of the most relevant

challenges envisaged for real-scale process design and implementation.

Laser Shock Processing of Metallic Alloys:

Process Overview and Development of Advanced

Applications through the Integrated CLUPM

Modelling-Processing-Testing Approach

OUTLINE:

•

Introduction

•

Summary on the Physical Basis of LSP Treatments

•

Predictive Assessment Methods developed at CLUPM

•

Experimental LSP Setup at CLUPM

•

Sample results on the treatment of Metallic Materials by LSP

•

The Integrated Modelling-Processing-Testing Approach for the

Design of LSP Treatments: Some Representative Examples

The UPM Laser Centre Approach to LSP Development

LASER-PLASMA

INTERACTION

SIMULATION

AND DIAGNOSIS

NUMERICAL SIMULATION

OF SOLID BEHAVIOUR AND

PROPERTIES TRANSFORMATION

PROCESSING AND

EXPERIMENTAL

CHARACTERIZATION OF

MATERIAL PROPERTIES

NUMERICAL SIMULATION. MODEL DESCRIPTION

The SHOCKLAS Calculational System

NUMERICAL SIMULATION. MODEL DESCRIPTION

HELIOS

HELIOS

Analysis of relative influence of confining material

CONSISTENT MODEL FOR CONFINED PLASMA EXPANSION IN LSP

3. NUMERICAL SIMULATION RESULTS

HELIOS

Analysis of plasma for LSP conditions

CONSISTENT MODEL FOR CONFINED PLASMA EXPANSION IN LSP

Ocaña, J.L. et al.: "Predictive assessment and experimental characterization of the influence of irradiation

parameters on surface deformation and residual stresses in laser-shock-processed metallic alloys".

Proc. SPIE 5448, 642-653 (2004)

1

9

17

25

1

9

17

25

SHOCK PROPAGATION AND DERIVED RESIDUAL STRESSES IN LSP

σ

_x

t = 10 ns; f = 10 Hz

Q-SWITCHED Nd:YAG LASER

î í ì = = = = J/pulse 1,4 E ; nm 532 λ 1064nm; E 2,5J/pulse λ

t = 10 ns; f = 10 Hz

Q-SWITCHED Nd:YAG LASER

î í ì = = = = J/pulse 1,4 E ; nm 532 λ 1064nm; E 2,5J/pulse λ

Laser

Mirror

Water

Supply

Lens

Test Piece

Martí-López, L. et al.: Appl. Optics, 48, 3671-3680 (2009)

2

d

1

xy

d

y

d

x

Δs

Δy

y

Δx

x

surface

treated

Total

pulses

of

Nº

EOD

Density

g

Overlappin

Equivalent

=

=

=

=

º

2

d

E

E

xy

d

y

d

x

E

Δs

Δy

y

Δx

x

surface

treated

Total

Energy

Pulse

pulses

of

Nº

EED

Density

Energy

Equivalent

=

=

=

×

=

º

2

d

4

π

2

d

2

4

π

surface

treated

Total

Area

Pulse

pulses

of

Nº

ELOF

factor

g

overlappin

local

Equivalent

÷

ø

ö

ç

è

æ

=

=

×

=

º

f

f

EXPERIMENTAL PROCEDURE

EA -XX -0 6 2 RE-1 2 0

CEA -XX -0 6 2 U M -1 2 0

EA -XX -0 6 2 RE-1 2 0

CEA -XX -0 6 2 U M -1 2 0

Residual Stresses Measurement Equipment (According to ASTM E837-08)

Residual Stresses (According to ASTM E837-08)

Al2024-T351

Ti6Al4V

Relatively broad difference between

S

and S

in Al2024-T351

Relatively small difference between

S

and S

in Ti6Al4V

EXPERIMENTAL RESULTS. Fatigue life enhancement of AISI 316L

Experimental setup LSP CLUPM

Process parameters

Wavelength

(nm)

1064

Frecuency (Hz)

10

Energy (J/pulse)

2.0

Pulse width (ns)

~ 9

Spot diameter (mm)

~ 1.5

Overlapping (pulses/cm

₎

900

1600

Confining medium

Water jet

Absorbent coating

No

1600 pulses/cm2 ₊ Heat treat.: 500 ˚C, 8h

Fatigue Tests:

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

100000

1000000

Base material

LSP 900

LSP 1600

Cycles to failure

S

(MP

a)

LogN=16.33764-4.79302LogS

R

_=0.99760

LogN=22.51020-7.35620LogS

R

_=0.98967

LogN=21.09071-0.01178S

R

_=0.87937

Residual Stresses:

0,0

0,2

0,4

0,6

0,8

1,0

-500

-400

-300

-200

-100

0

Steel AISI 316L, 900 pulses/cm2_{, l = 1064 nm}

2.8 J/pulse, spot diameter = 1,5 mm, water jet, no paint

Resi

du

al

st

resses

(M

Pa)

Depth (mm)

Smax, LSP treated + thermal aging

0,0

0,2

0,4

0,6

0,8

1,0

-500

-400

-300

-200

-100

0

Steel AISI 316L, 1600 pulses/cm2_{, l = 1064 nm}

2.8 J/pulse, spot diameter = 1,5 mm, water jet, no paint

Smax, As LSP treated

Smax, LSP treated + thermal aging

Resi

du

al

st

resses

(M

Pa)

Depth (mm)

Fatigue Tests:

150

200

250

300

100000

1000000

Steel AISI 316L, 1600 pulses/cm

_{, l = 1064 nm}

2.8 J/pulse, spot diameter = 1,5 mm, water jet, no paint

Pristine AISI 316L LSP 1600 LSP 1600 + Thermal Aging Log N=24.55449-8.1898Log S_a R2_=0.84671

N (Cycles to failure)

S a

(MP

a)

150

200

250

300

100000

1000000

N (Cycles to failure)

S a

(MP

a)

Steel AISI 316L, 900 pulses/cm

_{, l = 1064 nm}

2.8 J/pulse, spot diameter = 1,5 mm, water jet, no paint

The UPM Laser Centre Approach to LSP Development

LASER-PLASMA

INTERACTION

SIMULATION

AND DIAGNOSIS

NUMERICAL SIMULATION

OF SOLID BEHAVIOUR AND

PROPERTIES TRANSFORMATION

PROCESSING AND

EXPERIMENTAL

CHARACTERIZATION OF

MATERIAL PROPERTIES

Notch: 150 mm depth, 60º angle

I. Fatigue Life enhancement of notched Al2024-T351 specimens*

RS’s s

_y

state after treatment

RS’s s

_x

state after treatment

LSP Treatment Strategy 1

LSP Treatment Strategy 2

LSP Treatment Strategy 3

Strategy 1

Strategy 2

Strategy 3

LSP Treatment Strategy 1

LSP Treatment Strategy 2

LSP Treatment Strategy 3

I. Fatigue Life enhancement of notched Al2024-T351 specimens

Representation of s

and s

components of the residual stresses fields in a

treated specimen under selected parametric conditions.

Ocaña, J.L. et al.: J. Mat. Proc. Technol., 223, 8–15 (2015)

II.

Engineered induction of through-thickness compressive

residual stresses fields in thin Al2024-T351 sheets*

The UPM Laser Centre Approach to LSP Development: Examples

Representation of s

and s

components of calculated residual stresses in the front and rear

sides of single-side and double-side LSP treated specimens.

Ocaña, J.L. et al.: J. Mat. Proc. Technol., 223, 8–15 (2015)

The UPM Laser Centre Approach to LSP Development: Examples

II.

Engineered induction of through-thickness compressive

Simulation results showing the effect of double-side treatment on the s

and s

components of the

residual stresses induced through the whole thickness in a point of a LSP treated plate

Ocaña, J.L. et al.: J. Mat. Proc. Technol., 223, 8–15 (2015)

The UPM Laser Centre Approach to LSP Development: Examples

II.

Engineered induction of through-thickness compressive

residual stresses fields in thin Al2024-T351 sheets*

Complete through-thickness experimental RSs measurement results compared to corresponding

numerical simulation results in a point of a doubled side LSP treated plate

Ocaña, J.L. et al.: J. Mat. Proc. Technol., 223, 8–15 (2015)

The UPM Laser Centre Approach to LSP Development: Examples

II.

Engineered induction of through-thickness compressive

III. Derived enhancement of crack stopping by LSP retardation stripes*

The UPM Laser Centre Approach to LSP Development: Examples

Single-side-peened

Double-side-peened

The UPM Laser Centre Approach to LSP Development: Examples

Source: AIRBUS Operations GmbH / EADS IW

III. Derived enhancement of crack stopping by LSP retardation stripes*

The UPM Laser Centre Approach to LSP Development: Examples

Source:

AIRBUS Operations GmbH / EADS IW

Open challenges envisaged for real-scale process design and implementation

•

Experimentally validated 2D model-based laser-plasma interaction and plasma

dynamics assessment (i.e. locally dependent thermo-mechanical wave applied

to treated material).

•

In depth evaluation of confining layer breakdown thresholds, with detailed

consideration of the effect of different types of protective coatings (specially in

high EOD treatments).

•

Development of appropriate (experimentally tested) high rate (LSP typical)

dynamic material behaviour models.

•

In depth parametric analysis of processing windows and scaling laws for

different approaches (i.e. high to minimum EOD, EED).

•

Further experimental investigation of material transformations (i.e.

microstructure, surface and mechanical properties,.. ) under LSP.

•

In depth evaluation of thermal / mechanical stability of LSP induced material

properties transformations.

•

Further exploitation of the capability of LSP predictive assessment tools for

the design of concrete purpose oriented applications (i.e. through-thickness

compressive RSs fields for crack propagation arresting, surface defects

remediation, preventive LSP treatment for extended life,…..).

•

Important surface resistance and life cycle extension improvements in critical

high reliability components by LSP have been experimentally demonstrated.

The associate predictive assessment capabilities needed for adequate

process design have also been developed and used for

theoretical-experimental contrast.

•

In view of the important improvements reached in surface properties

(precursor of improved corrosion resistance) and fatigue life (all of them

resulting from the deep compressive residual stresses fields introduced by

the process), the LSP technique has to be recognized as a key technology for

the enhancement of materials and systems durability and reliability.

•

The integrated Modelling-Processing-Testing approach developed at CLUPM

has been reported in this presentation along with some examples in which the

capability of joint consideration of the different aspects involved in LSP

processes is important from the real-scale design point of view.

•

Despite the important research effort developed in the last years for the

practical implementation of LSP as an industrially mature technology, some

critical scientific and technological issues still remain open and deserve

further investigation, the described integrated approach being hoped to

positively contribute to an effective progress in this line.

1.

Ocaña, J.L. et al.: “Predictive assessment and experimental characterization of the influence of irradiation

parameters on surface deformation and residual stresses in laser shock processed metallic alloys”. In:

High-Power Laser Ablation V, Phipps C.R., Ed.. SPIE Vol. 5548, 642-653 (2004)

2.

Ocaña, J.L. et al.: Materials Science Forum, 539-543, 1116-1121 (2007)

3.

Morales, M. et al.: Surfaces and Coating Technology, 202 , 2257-2262 (2008)

4.

Morales, M. et al.: Applied Surface Science, 255, 5181–5185 (2009)

5.

Ocaña, J.L. et al.: “Design Issues of Engineered Residual Stress Fields and Associate Surface Properties

Modification by LSP in Al and Ti Alloys”. Proceedings of the Fifth International WLT-Conference on Lasers in

Manufacturing 2009. Munich, June 2009. A. Ostendorf et al. Eds.. pp. 387-392 (2009)

6.

Martí-López, L. et al.: Applied Optics, 48, 3671-3680 (2009)

7.

Ocaña, J.L. et al.: “Laser Shock Processing of Metallic Materials: Coupling of Laser-Plasma Interaction and

Material Behaviour Models for the Assessment of Key Process Issues”. In International Symposium on High Power

Laser Ablation 2010, C.R. Phipps, Ed. AIP Conference Proceedings, Vol. 1278, pp. 902-913 (2010)

8.

Morales, M. et al.: Materials Science Forum, 638-642, 2682-2687 (2010)

9.

Morales, M. et al.: International Journal of Structural Integrity, 2, 51-61 (2011)

10. Ocaña, J.L. et al.: Materials Science Forum, 706-709, 2565-2570 (2012)

11. Ocaña, J.L. et al.: Materials Science Forum, 783-786, 2376-2381 (2014)

12. Correa, C. et al.: International Journal of Fatigue, 70, 196–204 (2015)

13. Correa, C. et al.: International Journal of Fatigue, 79 ,1–9 (2015)

14. Correa, C. et al.: Materials & Design, 79, 106–114 (2015)

15. Ocaña, J.L. et al.: Journal of Materials Processing Technology, 223, 8–15 (2015)

16. Moreno-Díaz , C. et al.: Journal of Materials Processing Technology, 232, 9–18 (2016)

ACKNOWLEDGEMENTS

MAIN REFERENCES

Work partly supported by MINECO (Spain; Projects MAT2012-37782 and MAT2015-63974-C4-2-R),

EADS Spain and AIRBUS Operations GmbH.

Thank you very much

for your attention !

ありがとう

Material:

Al2024 T3

Pulses:

Æ

_{=1,5 mm; t=10 ns; f=10 Hz;}

E=1 J/pulse; I=1,41 GW/cm

2

Swept Area : 15x15 mm

2

; 2500 pulses/cm

2

Air

Water

Material:

Al2024 T3

Pulses:

Æ

_{=1,5 mm; t=10 ns; f=10 Hz;}

E=1 J/pulse; I=1,41 GW/cm

2

Swept Area : 15x15 mm

2

; 2500 pulses/cm

2

Air

Water

MAXIMUM LSP PRESSURE VS. PEAK LASER INTENSITY

0

5

10

15

20

0

2

4

6

8

10

Gas dynamics PIRRI73 (g=3/2)

Experimental data BERTHE99 (l =1064 nm; t = 25 ns) Experimental data BERTHE99 (l = 532 nm; t = 25 ns)

Confined Interaction FABBRO90 (g=5/2; a=0.2) Confined Interaction FABBRO90 (g=5/2; a=0.3) Confined Interaction FABBRO90 (g=5/2; a=0.4) Confined Interaction FABBRO90 (g=5/2; a=0.5)

Vacuum Interaction PHIPPS88 (l =1064 nm; t =10 ns) Vacuum Interaction PHIPPS88 (l =1064 nm; t = 5 ns) Vacuum Interaction PHIPPS88 (l = 532 nm; t =10 ns) Vacuum Interaction PHIPPS88 (l = 532 nm; t = 5 ns)

M

axi

m

um

P

ressu

re

to

A

l T

ar

get

(G

Pa)

LASER INTENSITY REAKDOWN THRESHOLD VS. INTERACTION TIME

1E-6

1E-5

1E-4

1E-3

0,01

0,1

1

10

100

1E10

1E11

1E12

1E13

l

_{= 532 nm}

l

_{= 1064 nm}

In

te

ns

ity

B

re

ak

dow

n

Thr

es

ho

ld

(W

/c

m

)

Interaction time (ns)

Ocaña, J.L. et al.: "Predictive assessment and experimental characterization of the influence of irradiation

Water / Aluminium; Nd:YAG (1064 nm),

t

_{= 9 ns, F= 84 J/cm}

_{, radius = 1.5 mm}

Evaluation of relative effects of thermal and mechanical waves on shocked material

Morales, M. et al.: Materials Science Forum, 638-642, 2682-2687 (2010)

Martí-López, L. et al.: Appl. Optics, 48, 3671-3680 (2009)

EXPERIMENTAL VALIDATION. DIAGNOSIS SETUP

0

2

4

6

0.0

0.5

1.0

1.5

2.0

Vel

oci

ty·

10

c

m/

s

Time (ms)

UPM Laser Centre

Komissarova (96)

Speed of sound in water

Spectroscopic system calibrated in wavelength with Hg lamp

and in intensity with Deuterium lamp

4. EXPERIMENTAL VALIDATION. DIAGNOSIS SETUP

Electron density determination via Stark effect of Al II line at 281.62 nm:

Delay from laser pulse

2 µs

3 µs

Distance from target

1 mm

20.4 10

cm

2.4 10

cm

6 mm

17.2 10

_cm

_{2.0 10}

_cm

EXPERIMENTAL VALIDATION. DIAGNOSIS SETUP

Electron temperature determination through Boltzmann plot of relative intensities of

Mg II lines at 279.5528 nm, 280.2704 nm, 292.8633 nm and 293.6509 nm:

Preliminary electron temperature distributions in the range of 1.0-1.5 eV (i.e. @ 11 600 - 17 400 K)

were found close to the target 2-3 ms after laser shut-down

Moreno-Díaz, C. et al.: J. Mat. Proc. Technol., 232, 9–18 (2016)

2790

2800

2810

2820

2830

2840

2850

0

5000

10000

15000

20000

25000

30000

35000

40000

2 ms after laser pulse 3 ms after laser pulse

M g II 2795. 5 nm Al II 2816. 2 nm

In

ten

si

ty

(a.

u.

)

Wavelength (nm)

Ti6Al4V

Ti6Al4V

30x20x10 mm

30x20x10 mm

Al2024

Al2024

-

-

T351

T351

30x20x8 mm

30x20x8 mm

Ti6Al4V

Ti6Al4V

30x20x10 mm

30x20x10 mm

Al2024

Al2024

-

-

T351

T351

30x20x8 mm

30x20x8 mm

900 pulses/cm

900 pulses/cm

1600 pulses/cm

1600 pulses/cm

2500 pulses/cm

2500 pulses/cm

5000 pulses/cm

5000 pulses/cm

Reported Analysis

EXPERIMENTAL RESULTS. Surface modification

900 pulses/cm

2

_{1600 pulses/cm}

2

_{2500 pulses/cm}

2

Surface Roughness (Microscopy): Al2024-T351

Surface Roughness (Topographic Confocal microscopy):

Al2024-T351

900 pulses/cm

2

_{1600 pulses/cm}

2

_{2500 pulses/cm}

2

No

treatment pulses/cm900 2 _pulses/cm1600 2 _pulses/cm2500 2

Pa (mm) 7.96 5.23 4.82 4.96

Microscopic material compactation: Al2024-T351

900 pulses/cm

2

_{1600 pulses/cm}

2

_{2500 pulses/cm}

2

Surface Roughness (Microscopy): Ti6Al4V

Surface Roughness (Topographic Confocal microscopy): Ti6Al4V

900 pulses/cm

2

2500 pulses/cm

2

_{5000 pulses/cm}

2

No

treatment pulses/cm900 2 _pulses/cm1600 2 _pulses/cm2500 2

Pa (mm) 9.98 3.62 3.87 3.87

<Dz> ---- 2.81 7.40 5.80

Microscopic material compactation: Ti6Al4V

Microhardness (HV)

Slight increase in microhardness in Al2024-T351

Higher for higher LSP treatement intensity

No apparent hardening effect in Ti6Al4V.

Wear resistance (According to ASTM G99-04)

Ti6Al4V

Inappreciable wear improvement in

Ti6Al4V at moderate loads

EXPERIMENTAL RESULTS. Surface modification

Considerable wear improvement in

10

100

0,00

0,02

0,04

0,06

0,08

0,10

Aluminium 6061-T6, 1064 nm

Spot diameter = 1.5 mm

2500 pulses/cm

1350 pulses/cm

900 pulses/cm

No LSP

2500 pulses/cm

1350 pulses/cm

900 pulses/cm

No LSP

da/

dN

(m

m

/cy

cl

e)

K (MPa . m

₎

Rubio-González, C. et al.: Mat. Sci. Eng. A., 386 (2004) 291-295

DISCUSSION AND OUTLOOK

Problem

Solution

DISCUSSION AND OUTLOOK

Geometry and FEM mesh used in the treatment of hip replacement by LSP.

Correa, C. et al.: Materials & Design, 79, 106 – 114 (2015)

IV. Computational Design of LSP Treatments for

Real High Reliability Components

Colour scale presentation of the minimum principal superficial residual stresses

predicted in hip replacement after LSP treatment.

Correa, C. et al.: Materials & Design, 79, 106 – 114 (2015)

IV. Computational Design of LSP Treatments for

Real High Reliability Components

Sample result showing the internal residual stresses fields predicted in a hip

replacement prosthesis after LSP treatment.

IV. Computational Design of LSP Treatments for

Real High Reliability Components

Sample of experimentally validated realistic calculational prediction of blade

deformation under different LSP conditions for complete component processing.

V. Computational Design of LSP Treatments for

Real High Reliability Components

Geometry checking sequence for the complete component processing.

V. Computational Design of LSP Treatments for

Real High Reliability Components

UNIVERSIDAD POLITÉCNICA DE MADRID

CENTRO LÁSER

Centro Láser U.P.M.

Campus Sur U.P.M.

Edificio Tecnológico "La Arboleda"

Carretera de Valencia km. 7,300

28031 Madrid - SPAIN

Tel. : (+34) 91 336 30 99

Fax.: (+34) 91 336 55 34

Email:

[email protected]

[email protected]