Laser shock processing: an emerging technique for the improvement of fatigue life and surface properties of high reliability metallic components

•Introduction •Process Experimental Setup •Experimental Procedure •Experimental Results for Al2024 - T351, Ti6Al4V and AISI 316L - Surface Roughness and Compactation - Residual stresses - Tensile Strength - Fatigue Life •Discussion and Outlook - Prospects for technological applications of LSP

Application of high-intensity short-pulse lasers to the mechanical and surface properties improvement of high reliability metallic components by shock processing

Outline: • Introduction • Process Experimental Setup • Experimental Procedure • Experimental Results for Al2024-T351 and Ti6Al4V - Residual stresses - Tensile Strength - Fatigue Life • Discussion and Outlook - Prospects for technological applications of LSP

Electric current of an electrified jet issuing from a long metallic tube.

This paper presents an analysis of the transport of electric current in a jet of an electrically conducting liquid discharging from a metallic tube into a gas or a vacuum, and subject to an electric field due to a high voltage applied between the tube and a far electrode. The flow, the surface charge and the electric field are computed in the current transfer region of the jet, where conduction current in the liquid becomes surface current due to the convection of electric charge accumulated at its surface. The electric current computed as a function of the flow rate of the liquid injected through the tube increases first as the square root of this flow rate, levels to a nearly constant value when the flow rate is increased and finally sets to a linear increase when the flow rate is further increased. The current increases linearly with the applied voltage at small and moderate values of this variable, and faster than linearly at high voltages. The characteristic length and structure of the current transfer region are determined. Order-of-magnitude estimates for jets which are only weakly stretched by the electric stresses are worked out that qualitatively account for some of the numerical results.

Laser Shock Processing: An Emerging Technique for the Enhancement of Surface Properties and Fatigue Life of High Strength Metal Alloys

Profiting by the increasing availability of laser sources delivering intensities above 10 9 W/cm 2 with pulse energies in the range of several Joules and pulse widths in the range of nanoseconds, laser shock processing (LSP) is being consolidating as an effective technology for the improvement of surface mechanical and corrosion resistance properties of metals and is being developed as a practical process amenable to production engineering. The main acknowledged advantage of the laser shock processing technique consists on its capability of inducing a relatively deep compression residual stresses field into metallic alloy pieces allowing an improved mechanical behaviour, explicitly, the life improvement of the treated specimens against wear, crack growth and stress corrosion cracking. Following a short description of the theoretical/computational and experimental methods developed by the authors for the predictive assessment and experimental implementation of LSP treatments, experimental results on the residual stress profiles and associated surface properties modification successfully reached in typical materials (specifically steels and Al and Ti alloys) under different LSP irradiation conditions are presented

Mechanical properties enhancement of high reliability metallic materials by laser shock processing

Laser shock processing (LSP) is being increasingly applied as an effective technology for the improvement of metallic materials surface properties in different types of components as a means of enhancement of their corrosion and fatigue life behavior. As reported in previous contributions by the authors, a main effect resulting from the application of the LSP technique consists on the generation of relatively deep compression residual stresses field into metallic alloy pieces allowing an improved mechanical behaviour, explicitly the life improvement of the treated specimens against wear, crack growth and stress corrosion cracking. Additional results accomplished by the authors in the line of practical development of the LSP technique at an experimental level (aiming its integral assessment from an interrelated theoretical and experimental point of view) are presented in this paper. Concretely, follow-on experimental results on the residual stress profiles and associated surface properties modification successfully reached in typical materials (especially Al and Ti alloys) under different LSP irradiation conditions are presented along with a practical correlated analysis on the protective character of the residual stress profiles obtained under different irradiation strategies and the evaluation of the corresponding induced properties as material specific volume reduction at the surface, microhardness and wear resistance. Additional remarks on the improved character of the LSP technique over the traditional “shot peening” technique in what concerns depth of induced compressive residual stresses fields are also made through the paper.

Development of a Uniform Theory of Diffraction for Scattered and Surface Electromagnetic Field Analysis on a Cylinder

Con esta tesis ”Desarrollo de una Teoría Uniforme de la Difracción para el Análisis de los Campos Electromagnéticos Dispersados y Superficiales sobre un Cilindro” hemos iniciado una nueva línea de investigación que trata de responder a la siguiente pregunta: ¿cuál es la impedancia de superficie que describe una estructura de conductor eléctrico perfecto (PEC) convexa recubierta por un material no conductor? Este tipo de estudios tienen interés hoy en día porque ayudan a predecir el campo electromagnético incidente, radiado o que se propaga sobre estructuras metálicas y localmente convexas que se encuentran recubiertas de algún material dieléctrico, o sobre estructuras metálicas con pérdidas, como por ejemplo se necesita en determinadas aplicaciones aeroespaciales, marítimas o automovilísticas. Además, desde un punto de vista teórico, la caracterización de la impedancia de superficie de una estructura PEC recubierta o no por un dieléctrico es una generalización de varias soluciones que tratan ambos tipos de problemas por separado. En esta tesis se desarrolla una teoría uniforme de la difracción (UTD) para analizar el problema canónico del campo electromagnético dispersado y superficial en un cilindro circular eléctricamente grande con una condición de contorno de impedancia (IBC) para frecuencias altas. Construir una solución basada en UTD para este problema canónico es crucial en el desarrollo de un método UTD para el caso más general de una superficie arbitrariamente convexa, mediante el uso del principio de localización de los campos electromagnéticos a altas frecuencias. Esta tesis doctoral se ha llevado a cabo a través de una serie de hitos que se enumeran a continuación, enfatizando las contribuciones a las que ha dado lugar. Inicialmente se realiza una revisión en profundidad del estado del arte de los métodos asintóticos con numerosas referencias. As í, cualquier lector novel puede llegar a conocer la historia de la óptica geométrica (GO) y la teoría geométrica de la difracción (GTD), que dieron lugar al desarrollo de la UTD. Después, se investiga ampliamente la UTD y los trabajos más importantes que pueden encontrarse en la literatura. As í, este capítulo, nos coloca en la posición de afirmar que, hasta donde nosotros conocemos, nadie ha intentado antes llevar a cabo una investigación rigurosa sobre la caracterización de la impedancia de superficie de una estructura PEC recubierta por un material dieléctrico, utilizando para ello la UTD. Primero, se desarrolla una UTD para el problema canónico de la dispersión electromagnética de un cilindro circular eléctricamente grande con una IBC uniforme, cuando es iluminado por una onda plana con incidencia oblicua a frecuencias altas. La solución a este problema canónico se construye a partir de una solución exacta mediante una expansión de autofunciones de propagación radial. Entonces, ésta se convierte en una nueva expansión de autofunciones de propagación circunferencial muy apropiada para cilindros grandes, a través de la transformación de Watson. De esta forma, la expresión del campo se reduce a una integral que se evalúa asintóticamente, para altas frecuencias, de manera uniforme. El resultado se expresa según el trazado de rayos descrito en la UTD. La solución es uniforme porque tiene la importante propiedad de mantenerse continua a lo largo de la región de transición, a ambos lados de la superficie del contorno de sombra. Fuera de la región de transición la solución se reduce al campo incidente y reflejado puramente ópticos en la región iluminada del cilindro, y al campo superficial difractado en la región de sombra. Debido a la IBC el campo dispersado contiene una componente contrapolar a causa de un acoplamiento entre las ondas TEz y TMz (donde z es el eje del cilindro). Esta componente contrapolar desaparece cuando la incidencia es normal al cilindro, y también en la región iluminada cuando la incidencia es oblicua donde el campo se reduce a la solución de GO. La solución UTD presenta una muy buena exactitud cuando se compara numéricamente con una solución de referencia exacta. A continuación, se desarrolla una IBC efectiva para el cálculo del campo electromagnético dispersado en un cilindro circular PEC recubierto por un dieléctrico e iluminado por una onda plana incidiendo oblicuamente. Para ello se derivan dos impedancias de superficie en relación directa con las ondas creeping y de superficie TM y TE que se excitan en un cilindro recubierto por un material no conductor. Las impedancias de superficie TM y TE están acopladas cuando la incidencia es oblicua, y dependen de la geometría del problema y de los números de onda. Además, se ha derivado una impedancia de superficie constante, aunque con diferente valor cuando el observador se encuentra en la zona iluminada o en la zona de sombra. Después, se presenta una solución UTD para el cálculo de la dispersión de una onda plana con incidencia oblicua sobre un cilindro eléctricamente grande y convexo, mediante la generalización del problema canónico correspondiente al cilindro circular. La solución asintótica es uniforme porque se mantiene continua a lo largo de la región de transición, en las inmediaciones del contorno de sombra, y se reduce a la solución de rayos ópticos en la zona iluminada y a la contribución de las ondas de superficie dentro de la zona de sombra, lejos de la región de transición. Cuando se usa cualquier material no conductor se excita una componente contrapolar que tiende a desaparecer cuando la incidencia es normal al cilindro y en la región iluminada. Se discuten ampliamente las limitaciones de las fórmulas para la impedancia de superficie efectiva, y se compara la solución UTD con otras soluciones de referencia, donde se observa una muy buena concordancia. Y en tercer lugar, se presenta una aproximación para una impedancia de superficie efectiva para el cálculo de los campos superficiales en un cilindro circular conductor recubierto por un dieléctrico. Se discuten las principales diferencias que existen entre un cilindro PEC recubierto por un dieléctrico desde un punto de vista riguroso y un cilindro con una IBC. Mientras para un cilindro de impedancia se considera una impedancia de superficie constante o uniforme, para un cilindro conductor recubierto por un dieléctrico se derivan dos impedancias de superficie. Estas impedancias de superficie están asociadas a los modos de ondas creeping TM y TE excitadas en un cilindro, y dependen de la posición y de la orientación del observador y de la fuente. Con esto en mente, se deriva una solución UTD con IBC para los campos superficiales teniendo en cuenta las dependencias de la impedancia de superficie. La expansión asintótica se realiza, mediante la transformación de Watson, sobre la representación en serie de las funciones de Green correspondientes, evitando as í calcular las derivadas de orden superior de las integrales de tipo Fock, y dando lugar a una solución rápida y precisa. En los ejemplos numéricos realizados se observa una muy buena precisión cuando el cilindro y la separación entre el observador y la fuente son grandes. Esta solución, junto con el método de los momentos (MoM), se puede aplicar para el cálculo eficiente del acoplamiento mutuo de grandes arrays conformados de antenas de parches. Los métodos propuestos basados en UTD para el cálculo del campo electromagnético dispersado y superficial sobre un cilindro PEC recubierto de dieléctrico con una IBC efectiva suponen un primer paso hacia la generalización de una solución UTD para superficies metálicas convexas arbitrarias cubiertas por un material no conductor e iluminadas por una fuente electromagnética arbitraria. ABSTRACT With this thesis ”Development of a Uniform Theory of Diffraction for Scattered and Surface Electromagnetic Field Analysis on a Cylinder” we have initiated a line of investigation whose goal is to answer the following question: what is the surface impedance which describes a perfect electric conductor (PEC) convex structure covered by a material coating? These studies are of current and future interest for predicting the electromagnetic (EM) fields incident, radiating or propagating on locally smooth convex parts of highly metallic structures with a material coating, or by a lossy metallic surfaces, as for example in aerospace, maritime and automotive applications. Moreover, from a theoretical point of view, the surface impedance characterization of PEC surfaces with or without a material coating represents a generalization of independent solutions for both type of problems. A uniform geometrical theory of diffraction (UTD) is developed in this thesis for analyzing the canonical problem of EM scattered and surface field by an electrically large circular cylinder with an impedance boundary condition (IBC) in the high frequency regime, by means of a surface impedance characterization. The construction of a UTD solution for this canonical problem is crucial for the development of the corresponding UTD solution for the more general case of an arbitrary smooth convex surface, via the principle of the localization of high frequency EM fields. The development of the present doctoral thesis has been carried out through a series of landmarks that are enumerated as follows, emphasizing the main contributions that this work has given rise to. Initially, a profound revision is made in the state of art of asymptotic methods where numerous references are given. Thus, any reader may know the history of geometrical optics (GO) and geometrical theory of diffraction (GTD), which led to the development of UTD. Then, the UTD is deeply investigated and the main studies which are found in the literature are shown. This chapter situates us in the position to state that, as far as we know, nobody has attempted before to perform a rigorous research about the surface impedance characterization for material-coated PEC convex structures via UTD. First, a UTD solution is developed for the canonical problem of the EM scattering by an electrically large circular cylinder with a uniform IBC, when it is illuminated by an obliquely incident high frequency plane wave. A solution to this canonical problem is first constructed in terms of an exact formulation involving a radially propagating eigenfunction expansion. The latter is converted into a circumferentially propagating eigenfunction expansion suited for large cylinders, via the Watson transformation, which is expressed as an integral that is subsequently evaluated asymptotically, for high frequencies, in a uniform manner. The resulting solution is then expressed in the desired UTD ray form. This solution is uniform in the sense that it has the important property that it remains continuous across the transition region on either side of the surface shadow boundary. Outside the shadow boundary transition region it recovers the purely ray optical incident and reflected ray fields on the deep lit side of the shadow boundary and to the modal surface diffracted ray fields on the deep shadow side. The scattered field is seen to have a cross-polarized component due to the coupling between the TEz and TMz waves (where z is the cylinder axis) resulting from the IBC. Such cross-polarization vanishes for normal incidence on the cylinder, and also in the deep lit region for oblique incidence where it properly reduces to the GO or ray optical solution. This UTD solution is shown to be very accurate by a numerical comparison with an exact reference solution. Then, an effective IBC is developed for the EM scattered field on a coated PEC circular cylinder illuminated by an obliquely incident plane wave. Two surface impedances are derived in a direct relation with the TM and TE surface and creeping wave modes excited on a coated cylinder. The TM and TE surface impedances are coupled at oblique incidence, and depend on the geometry of the problem and the wave numbers. Nevertheless, a constant surface impedance is found, although with a different value when the observation point lays in the lit or in the shadow region. Then, a UTD solution for the scattering of an obliquely incident plane wave on an electrically large smooth convex coated PEC cylinder is introduced, via a generalization of the canonical circular cylinder problem. The asymptotic solution is uniform because it remains continuous across the transition region, in the vicinity of the shadow boundary, and it recovers the ray optical solution in the deep lit region and the creeping wave formulation within the deep shadow region. When a coating is present a cross-polar field term is excited, which vanishes at normal incidence and in the deep lit region. The limitations of the effective surface impedance formulas are discussed, and the UTD solution is compared with some reference solutions where a very good agreement is met. And in third place, an effective surface impedance approach is introduced for determining surface fields on an electrically large coated metallic circular cylinder. Differences in analysis of rigorouslytreated coated metallic cylinders and cylinders with an IBC are discussed. While for the impedance cylinder case a single constant or uniform surface impedance is considered, for the coated metallic cylinder case two surface impedances are derived. These are associated with the TM and TE creeping wave modes excited on a cylinder and depend on observation and source positions and orientations. With this in mind, a UTD based method with IBC is derived for the surface fields by taking into account the surface impedance variation. The asymptotic expansion is performed, via the Watson transformation, over the appropriate series representation of the Green’s functions, thus avoiding higher-order derivatives of Fock-type integrals, and yielding a fast and an accurate solution. Numerical examples reveal a very good accuracy for large cylinders when the separation between the observation and the source point is large. Thus, this solution could be efficiently applied in mutual coupling analysis, along with the method of moments (MoM), of large conformal microstrip array antennas. The proposed UTD methods for scattered and surface EM field analysis on a coated PEC cylinder with an effective IBC are considered the first steps toward the generalization of a UTD solution for large arbitrarily convex smooth metallic surfaces covered by a material coating and illuminated by an arbitrary EM source.

Induction of engineered residual stresses fields and enhancement of fatigue life of high reliability metallic components by laser shock processing

Laser shock processing (LSP) is being increasingly applied as an effective technology for the improvement of metallic materials mechanical and surface properties in different types of components as a means of enhancement of their corrosion and fatigue life behavior. As reported in previous contributions by the authors, a main effect resulting from the application of the LSP technique consists on the generation of relatively deep compression residual stresses field into metallic alloy pieces allowing an improved mechanical behaviour, explicitly the life improvement of the treated specimens against wear, crack growth and stress corrosion cracking. Additional results accomplished by the authors in the line of practical development of the LSP technique at an experimental level (aiming its integral assessment from an interrelated theoretical and experimental point of view) are presented in this paper. Concretely, follow-on experimental results on the residual stress profiles and associated surface properties modification successfully reached in typical materials (especially Al and Ti alloys characteristic of high reliability components in the aerospace, nuclear and biomedical sectors) under different LSP irradiation conditions are presented along with a practical correlated analysis on the protective character of the residual stress profiles obtained under different irradiation strategies. Additional remarks on the improved character of the LSP technique over the traditional “shot peening” technique in what concerns depth of induced compressive residual stresses fields are also made through the paper

Thermoelectric assessment of laser peening induced effects on a metallic biomedical Ti6Al4V

Laser peening has recently emerged as a useful technique to overcome detrimental effects associated to another well-known surface modification processes such as shot peening or grit blasting used in the biomedical field. It is worth to notice that besides the primary residual stress effect, thermally induced effects might also cause subtle surface and subsurface microstructural changes that might influence corrosion resistance. Moreover, since maximum loads use to occur at the surface, they could also play a critical role in the fatigue strength. In this work, plates of Ti-6Al-4V alloy of 7 mm in thickness were modified by laser peening without using a sacrificial outer layer. Irradiation by a Q-switched Nd-YAG laser (9.4 ns pulse length) working in fundamental harmonic at 2.8 J/pulse and with water as confining medium was used. Laser pulses with a 1.5 mm diameter at an equivalent overlapping density (EOD) of 5000 cm-2 were applied. Attempts to analyze the global induced effects after laser peening were addressed by using the contacting and non-contacting thermoelectric power (TEP) techniques. It was demonstrated that the thermoelectric method is entirely insensitive to surface topography while it is uniquely sensitive to subtle variations in thermoelectric properties, which are associated with the different material effects induced by different surface modification treatments. These results indicate that the stress-dependence of the thermoelectric power in metals produces sufficient contrast to detect and quantitatively characterize regions under compressive residual stress based on their thermoelectric power contrast with respect to the surrounding intact material. However, further research is needed to better separate residual stress effects from secondary material effects, especially in the case of low-conductivity engineering materials like titanium alloys.