SHOTPEENING

Forlongerfatiguelife

Shot Peening allows metal parts to accept higher

loads or to endure a longer fatigue life in service
withoutfailure.Inusualapplicationsshotpeeningcan
be done without changing the part design or its
material.

Ifyoustrikeapartsurfacewitharoundedobjectata
velocity,sufficienttoleaveanimpressionandcontinue
until you completely cover (cold work) the entire
surfacethenyouwillhavepeenedthatpart.

Inmodernusagepeeningisappliedbythrowingtinycaststeelballsorshotathighvelocity
hencethetermshotpeening.

Actuallytheeffectofpeeningwasdiscoveredcenturiesagobyswordsmithsandblacksmiths
whofoundthepeeningthesurfaceofaswordorwagonspringwouldgreatlyincreaseits
resistancetobreakingwhenbentorloadedrepeatedly.Thereasonsforthisimprovementwere
not then understood. The round knob of the ball peen hammer was the smiths tool for
applyingthisprocesstocold(nothot)parts.

WHEREISSHOTPEENINGUSED?
Mostpeopledonotknowthatinthecartheydriveallthecoil,leafandvalvespringshave
been shot peened as well as the torsion rods, drive shafts, axles, and gears. IN some
vehiclestheconnectingrods,andcrankshaftarepeenedaswell.

Ifyoufly,shotpeeningalsocontributestotheintegrityofmanyoftheplanespartsandto
yoursafetyforshotpeeningworksitswondersonaaluminumandtitaniumaswellassteel
parts. The wind sins and structural members will have been shot peened to improve their
fatiguepropertiesaswellastopreventstresscorrosioncracking.Thelandinggearisshot
peenedandmostpartsinthejetenginesalso.

Iftheplaneisawidebodytypethewingskinswillhavebeenformedtotheairfoilcontours
byaprocesscalledpeenforming.Thisamazingprocessissocostaffectiveandversatilethat
the wings of new aircraft designs are possible the forming of very long tapered skins
includingpositiveornegativedihedralbreaksvirtuallywithouttooling,andthesideeffects(
additionofcompressivestresses)arebeneficialnotdetrimental.

Whenathinpartispeenedononesidethecompressivestresslayerhastheeffectoftrying
toelongatethepeenedsurfaceandtherebycurvesthepart.Thecurvethenwilldevelopwith
theconvexsidetowardtheincomingshot.Peenformingisbasedonthiseffect.

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Peeninghaslittleornoeffectonstaticallyloadedstructuressuchasbuildingsorbridges.It
worksbestforcyclicallyloadedparts(whereloadreversalsoccurfrequently).

Railroadwheels,rotaryprintingpressplates,aircraftpropellers,highstrengthfasteners,rock
drillingbits,anddrillrodsaretypicallypeenedparts.

ShotPeeningForLongerFatigueLife
Itisrarethatwegofromoneplacetoanotherbyroadandnotfindavehicle,eithera
lorryoracarbrokedownontheroadduetofatiguefailureofaxleshaftorthespringandso
on,thuscreatingobstaclesintheflowoftrafficandsometimesresultinginseriousaccidents.
These fatigue failures can be reduced and are being almost eliminated in the Western
countriesbytheadoptionofshotpeeningprocessforincreasingthefatiguelifeofvarious
componentssubjectedtofatiguestress.

Shotpeeningisjustoneoftheapplicationsofshotblastingforincreasingthefatiguelifeof
various components subject to fatigue stress. The reduced fatigue failures result in low
maintenanceandreplacementcostforpartslikesprings,gears,axlesandknucklejointsetc.

Asiswellknown,thepartwhichhfailsinfatigue,failsmainlyduetoitsfailureintensile
strength.Justasinprestressedconcreteattheendofshotpeening,thepartsareleftwith
residualcompressivestress.Whenthecomponentissubjectedtothetensileload,aportion
ofthetensilestressessetbytheloadisneutralizedbytheresidualcompressivestressesleft
bytheshotpeening.Thustheeffectiveloadisgreatlyreduced,resultinginanincreased
fatiguelifeeventotheextentof1,500percent,ormore.

Manufacturersofswordsandbrassutensilsarewellknownfortheirdentingthesurfaceof
theswordsortheutensilsforbetterlifebyroundheadedhammerscalledballpeenhammers.
Todaythisisnotdonebyhammersbutbyveryfastmovingmetallicshots.Shotpeeningisa
coldworkingmethodaccomplishedbypeltingthesurfaceofametalpartwithroundmetallic
shotthrownatarelativelyhighvelocity,bymeansofanAirlessWheelabratorCentrifugal
wheel.

Eachshotactsasatinypeenhammer,makingasmalldentinthesurfaceofthemetaland
stretchingthesurfaceradiallyasithits.Theimpactoftheshotcausesaplasticflowofthe
surfacefibresextendingtoadepthdependinguponthedegreeofimpactoftheshotand
thephysicalpropertiesofthework.Depthsvaryingfrom.005to.030arerathercommon,
butvalueseitherhigherorlowerthanthisrangecanbepractical.Thereismomentaryriseof
temperatureofthesurfaceduetotransformationofenergy,possiblyenoughtoaffectthe
plasticflowofsurfacefibres;however,theeffectofshotpeeningisknownascoldworking
todistinguishitfrommetalflowathightemperatures.

The fibres underneath the top layer, however, are not stretched to their yield point and,
therefore,retainelasticity,theunderfibresare,ofcourse,bondedtothestretchedsurface
layerandaftertheinnerfibresforcetheouterfibrestoreturntoashorterlengththanthat

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atwhichthestretchedfibreswouldtendtoremain,intheequilibriumwhichresults,the
surfacefibresareinresidualcompressionwhiletheinnerfibresareintension.

Thesurfacecompressionstressisseveraltimesgreaterthanthetensionstressintheinterior
of the section; so that when working stresses are applied that would ordinarily impose a
tensionstressonthesurface,thattensionisoffsetbytheresidualstressinthesurfacelayer,
andsinceasmentionedbeforethefatiguefailuresgenerallyresultformtensilestresses,not
formcompressivestress,thenetresultisconsiderablygreaterfatiguestrength.

Shotpeeningisnowadaysusedwithhundredsofdifferentcomponentssomeofwhichare
givenhere.Railwayleafsprings,automobileleafsprings,helicalspringsofalltypes,Gearsof
alltypes,axlebearings,crankshafts,pneumaticdrills,millingcutters,connectingrods,cylinder
blocksandvaluespringswashersetc..

Mostoftheshotblastingequipmentcouldbeutilizedforshotpeeningwiththeproper
arrangementoftheshotseparator.Besidestherearespecialshotpeeningmachinestosuit
thespecificrequirementofparticularsizesandshapesoftheproductandthequantityof
theproducttobeshotpeened.

HOWDOESSHOTPEENINGHELP?
Whenaroundpart(steelball)strikesapartofsurfaceathighvelocitythecontactareaisa
point.Thisconcentratestheimpactenergyinaverysmallarea.Partofthisenergyiswastedin
deformingandbouncingtheballbutasignificantamountistransferredintothepartbeing
struckcausingaradialplasticflowattheimpactpointandmayevenleaveasmallvisible
crater. This plastic flow or movement of metal leaves compressive stresses in the part.
Completecoverageofthewithoverhaulingballimpactsleavesathinpermanentcompressive
stresslayerinthepartsurface.

Metalsfailundertension(pullapart)loadsandnotundercompressive(pushtogether)loads
andnotundercompressive(pushtogether)loads.Thefailurecrackwillusuallyinitiateatthe
part surface where tension stresses are highest and a stress riser exists ( scratch, dent,
machinemark,etc..). Whenparts whichhavebeenshot peenedareloaded,thefailure
producingtensilestressesarethusreducedbytheamountofthecompressivestressespre
existinginthepartsurface.Thisloweringoftheeffectivetensilestresswillthenallowthe
parttoaccepthigherloadingortoextenditsservicelifesignificantly.

When the depth of the induced compressive stress layer exceeds the dept of all surface
discontinuities(stressrisers)theirabilitytostartacrackiseffectivelymasked.Thisisavery
importantsecondarybenefit.

SHOTPEENINGTODAYISAPRECISIONPROCESS
Shot peening is the bombarding of a metal component by small spherical or noncutting
particles,resultinginplasticdeformationandthesettingupofacompressivestressinthe
peenedsurface.Itisacoldworkingprocessmostcommonlyusedtopreventfatiguefailure

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andtoincreasethefatiguelifeofcomponentsundercyclicstressconditions.Thecompressive
stressimpartedinthesurfacebypeeningservestoinhibitorreducetensilestressesinthe
area where material failure would normally develop. The resulting increase in the
componentfatiguelifeisinsomecasesknowntobeashighas1500%.

Peeningcanbeachievedbypropellingtheshotcentrifugallybymeansofanimpeller,or
pneumatically in high pressure airstream using a pressure fed or ejector nozzle. Modern
automatic peening machines are capable of projecting millions of steel or glass beads in
seconds.

Therearenumerousapplicationswherethecompressivestressproducedbypeening,which
canbeasmuchashalftheyieldstrengthofthematerial,isofsizeandconditionofthe
peening media, the time the workpiece is exposed to the blast stream, the size and
configuration of the nozzles, angles, distances and other related factors it is possible to
control accurately the depth of the compressed layer, the distribution o f stress and in
consequence,thegreaterlifeexpectationoftheworkpiece.

Intheaerospaceindustry,forexample,wherepartssuchasaircraftundercarriagelegsare
shotpeened,theshotpeeninglegsareshotpeened,theshotpeeningneedstobecarried
outtoverystrictspecificationstomeetsafetyrequirementslaiddownbyairlinesandaircraft
manufacturers. This is an extreme case, and there are many applications of shot peening
wherethecontrolisnotsovitallyimportant,butneverthelessitisstillrequiredtoensure
consistencyofpeeningintensityfromonecomponenttothenexttomeetqualitycontrol
requirements.

SHOTPEENINGINTENSITY:

Ifoneimaginesastreamofsphericalparticlesleavingablastnozzleoracentrifugalblasting
machineandstrikingametalsurface,theworkdonetothesurfacedependsonanumberof
factors.Sizeandmaterialofthesphericalshotisimportant,asisitsvelocityandtherate
andangleatwhichtheblastpatternsweepsacrossthesurface.Therelativeworkdonetothe
surface is called the Peening intensity. Obviously it is impractical to count and weigh the
particlesandmeasuretheirvelocity,soasimplercomparativemethodhasbeendevicedto
measurepeeningintensity.

Ifaflatstripofmetalisshotpeenedononesideonlyitwillslightlycurlawayfromthe
sidewhichhasbetreatedandproduceaconvexsurface.Ifastandardstripisused,the
degreeofcurvatureisameasureofthepeeningintensity,thestripecurlingmoreathigher
intensities.ThestandardstripiscalledanAlmenStripafterthemanwhofirstformalizedthis
method. It is made from spring steel of carefully controlled quality to a size within close
tolerances.ItisusedinthreethicknesscalledC,AandN.TheCstripisthickestandNstrip
thethinnest.Thecurvatureorareheight,ofthestripismeasuredwiththeaidofadial
gauge Fig.1 after the strip is placed and retained magnetically against two pairs of ball
contactsafixeddistanceapart.Thegaugeiszeroedwiththeunpeenedstripinposition.
After peening peening the strip is replaced against the contacts with the unpeened side

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towardsthedialgaugestemandtheAlmenareheightisreaddirectlyinthousandsthsofan
inchormillimeters.

The three different strip thicknesses are to cater for different extremes of peening intensity. For
mostapplicationsanAstripwouldbeused,andifthisgaveadeflectionafterpeeningof
0.015inthiswouldbeexpressedas0.015inA,lighterpeening,givinglessthan0.006inA,
anNstripwouldbeused.TheCstripisforheavypeeningofanintensity,greaterthan0.23
inA.Generally,areheightNisthreetimesareheightAandaCreadingis0.3ofthaton
anAstrip.Inpractice,80%ofallpeeningrequirementsliebetween0.012inAand0.020in
A.

WhenpeeningintensityismeasureditisimportanttosubjectonesideoftheAlmenstripto
exactly the same blast conditions as the object to be peened. To do this the strip is
clampedbytheheadsoffourscrewstoaheavyflatblockofhardenedtoolsteel,calledan
Almenblock,Fog..Theassemblyisthenpassedthroughtheblaststreaminthesamemanner
andrelativepositionastheparttobepeened.Onirregularlyshapedcomponentsoftenmore
thanonestripisused,eachonepositionedonadifferencefacerequiringtreatment.

PEENINGSATURATION
Althoughpeeningintensitydependsonafactorsconcernedwiththeshotblastequipment
(pressure,shotsize,andsoon)thetimeofexposuretoashotblaststreamisalsovery
important.Thegraph,Fig.3showshowpeeningintensity(Almenareheight)increases
withexposuretime.Thepeeningintensityincreasedwithtimeuntilasaturationpointsis
reachedwhereanyincreaseinexposuretimeofthesamplestotheblastonlyresultsina
marginalincreaseinpeeningintensity.Ifcontinuedblastingforalongperiodoftimedoes
notproducedarequiredAlmenarcheight,thansaturationpointhasbeenreachedandeither
a larger shot size is required or a higher shot velocity to increase the Almen arc ( at
saturation).Inpractice,specificationsofpeeningintensityshouldalwaysbeforsaturation
values.

PEENINGCOVERAGE:

Itisessentialifthemaximumbenefitfromshotblastingistobeobtainedthatthesurface
iscompletelyanduniformlycoveredbytheminuteindentationsresultingfrombombardment
by the peening media. Generally, a peening specification should state the percentage
coveragerequiredandthiswouldbeestimatedbyinspectingthepeeningsurfacewiththeaid
ofmagnifyingglassorpreferably,amicroscope.Mostspecifications,particularlythoseused
in the safety conscious aerospace industry, will call for a 100% coverage. At least 90%
coveragewillprobablyberequiredforlessstringentrequirements.Asampleofstainlesssteel
peenedto100%coverageisshowninFig..Thecharacteristiccrateredappearancecanbe
clearlyseenintheillustration.

PEENINGMEDIA

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To accomplish a shot peening job efficiently, shot of the correct material and size
maintainedinaconditionfreeofcuttingedges,shouldbeused.Shotofpeeningisavailable
inavarietyofmaterialsdependingonthenatureofthejobinhand.

Caststeelshotisgenerallyusedforpeeningferrouscomponentsleaforcoilsprings,for
example or for the treatment of nonferrous articles when the possibility of ferrous
contamination is acceptable. It is however possible to blast components with angular non
ferrousabrasiveafterpeeningwithcaststeelshottoremoveanyferrouscontamination.This
isnotgenerallydone,sinceitwouldprobablybecheapertopeenthearticlewithglass
beadsinthefirstinstance.

Glassbeadsarewidelyusedforpeeningnonferrouscomponentsorwhereverylowintensities
may be required, for example on aluminum and its alloys, titanium and stainless steel,
particularlyintheaerospaceindustrywherepeeningiswidelyusedtoincreasethefatiguelife
onnonferrouscomponents.TheregularityofsizeandshapecanbeclearlyseeninFig.5.

Coppedwireislesswidelyusedforpeeningandconsistsofspringsteelwire,orpianowire,
shoppedintolengthsequaltoitsdiameter.Beforebeingusedforpeeningithastobeblasted
againstasteelplatetobluntthesharpcutends.

SHOTSIZES
Apartfromconsiderationsofpeeningintensity,whicharedirectlyaffectedbyshotsizethe
sizeofshotshouldbesmallenoughtofitthesmallestinsideradiusorfilletbeingpeened,
preferablylessthanonethirdofthefilletradius,Fig.6.Inaddition,itsdiametershouldnot
exceed one third of the fillet that of the smallest used including of course, the nozzle
throughwhichtheshotispropelled.

Tomaintaintherequiredstandardofpeeningintensityitisvitallyimportantthatthesize
rangeofshotisthatvirtuallyallshatteredparticlesareremoved.Inbetterqualityshot
blastequipmentthisisachievedbyanefficientairwashsystemwhichremovesundersize
particlesbypassingacontrolledairstreamthroughafallingstreamofpeeningmediawhich
ahsbeenprecipitated bycentrifugalmeansinacyclone. Forfinaleliminationofoversize
unwanteddebris,thereusableparticlespassthroughavibratedsieve.

PEENINGANDTHEDESIGNER
Mainapplicationofshotpeeningistoincreasethefatiguelifeofcomponentsundercyclicstress.
Theprocesswillprovideoptimumbenefitsatthedesignstageofacomponent.Peeningcan
beusefullyemployedwithinthecontextofextendingfatiguelifeintwoways.Eitherthefatigue
life of an existing component which has revealed premature failure can be reduced
considerablytogivethesamefatiguelife.Itisthelatterconceptthatisofinteresttothe
designer.

Generallyspeakingheisnotinterestedinunnecessarilyincreasingthecomponentsfatigue
life.Heis,however,veryinterestedinunnecessarilyincreasingthecomponentsfatiguelife.Heis

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however,veryinterestedinreducingitssize,andhencecost,inthefirstinstancewhilestill
retainingthesamelifecharacteristics.Inaddition,componentweightwillbereducedwhichis
ofcoursevitalintheaerospaceindustry.

SELECTIVETREATMENT:

It is not always necessary to peen an article all over. This is particularly true where a
componenthasanareaoffparticularlyhighstress,inwhichcaseonlythehighlystressed
area need be peened. If selected areas only are being peened care must be taken when
blending the peened and unpeened areas. An instance is where an article could be
experiencingachangingstresswhichisnotcyclicinasmuchasthestressdoesnotreverse.
Acaseinpointisamotorvehicleleadspring,whereonesideisconstantlyundertension
which(isamotorvehicle)isalwaysfluctuatingduringuse.Inthiscase,fatiguefailurecould
still occur, but only form the tension side and peening need only be carried out on the
tensionsidetoproducealayerundercompressivestress.Ifonevisualizestheloadedspring,
theothersideisalwaysundercompressivestress.Evengreaterbenefitcanbeobtainedby
peeningwiththecomponentunderstress.Whenthecomponentisthenreleased,thedepth
of the peened compressive layer is greater then would have been the case for normal
peeningandagreaterfatigueresistanceresults.

AIRBLASTCENTRIFUGAL
Maindifferencebetweenairblastandcentrifugalmachinesisthatthelatterdonotpropel
eachparticletoavelocityashighasthatwithairblast,buttheyproduceablastpattern
containingmanymoreparticles.Thismeansthattheycanhandleamuchgreaterthroughput
ofworkthananairblastmachine,buttoobtainthesamepeeningintensityalargershot
sizewouldprobablyneedtobeused.Additionally,thelargerpatternofblastwithvarying
shotvelocitiesfromthecentretotheedgesofthepatternproducesvariablepeeningintensities
over the total which for some components would be unacceptable. For many items,
however,whenpeeningtosaturation,thisisnotacriticalfactor.

Centrifugal machines are widely used for heavy peening applications. Typical examples are
largecoilsprings,torsionbarsandleafsprings.Formoredelicatecomponentslikevalve
springs,pushrodsandrocketarms,theprecisionofairblastsystemsmaybepreferred.

Itisimportanttohaveairpressureregulationonanairblastmachine.Withthisfacilityany
requiredpeeningintensitycaneasilybeachievedbyaselectedcombinationofshotsizeand
airpressure.Equallyimportantistherateoffeedingoftheshotthroughthenozzle.Itis
importantthatanevencontrolledfeedismaintained,andthattheorificethroughwhichthe
shot passes into the compressed air stream is either fully adjustable, or designed to
accommodate a wide variation in shot size while still keeping the appropriate feed rate.
Further considerations are the orifice and angle of the nozzle from the workpiece. To
reproducepeeningintensitiesaccuratelyallthesefactorsshouldbespecified.

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Generallycentrifugalmachinesareusedwithsteelshotorcutwire.Untilrecentlyithasnot
beenpossibletouseglassbeadsonthemtoavoidcontaminationofnonferrousworkpieces.
Mainreasonforthisisthatthelighterbeadscouldnotbereclaimedbutweredrawninto
the dust collection system to be wasted. This is particularly undesirable since glass bead
peeningmediaismoreexpensivethanironorsteelshot.Anadditionaldifficultyisthatthe
beads,beinglighterthansteelspheres,aresloweddownbyatmosphericdragonleavingthe
impeller,withconsequentreductioninpeeningintensities.

Thedifficultyofreclaimingglassbeadsforfurtherusehasbeensolvedintwoways,byusing
acentrifugalprecipitatorthroughwhichallairmustpassbeforereachingthedustcollector,
andbyconveyingthebeadsforreuseonafluidizedbedincorporatinganefficientclassifying
systemforremovinganyremainingdustandbrokenbeadparticles.Atubularimpellerhas
beendevelopedforpropellingthebeadssoastooffsettheslowingdowncausedbyairdrag
(seemetalworkingproduction,April1973,P.101).Theuseofimpellertubesinsteadofflat
bladeshastwoadvantages.Firstly,thetrackwidthproducedparalleltotheaxisofthewheel
is version, with a much greater, up to 100%, peak intensity at the centre. Secondly,
distribution of the blast pattern over its length normal to the axis of the wheel, shows a
greaterareaofhighintensitythanfromabladedversion.Thisisespeciallynoticeablewhen
usingfinemedia.

PEENINGISVERSATILE
Oftenatechniquebecomesassociatedwithastrictlylimitednumberofapplications.This
leadstobethecasewithshotpeening,whereeverydayproceduressuchasthetreatmentof
crankshafts,gearsandspringsisthoughtbymanytobethefullextentoftheprocess.In
scopeandscalethevarietyofshotpeeningapplicationsisconsiderable.Itrangesfromthe
treatment of large aircraft undercarriage components to delicate miniaturized electronic,
componentssubjecttostress,whichareshotpeenedwithtinyglassspheresrangingfrom45
to75micron.

Nor are the applications confined to the classis fatigue situation, where a component
undergoes a cyclic stress and shot peening increases fatigue life. There are other surface
defectsthatcausemetaltofailwhichcanbeinhibitedbyacarefullycontrolledpeening
process.Stresscorrosioncrankingisaproblemthatoccursasaresultofappliedstressona
component in a corrosive environment. Failure would not occur in the corrosive
environmentalonenorundertheappliedstressonly.Itisthecombinationthatcausesthe
problems.Iffailurecannotbepreventedbypeening,lifetofailurewillbecertainlyincreased.

Thepeeningofbearingstoimprovefatiguelifeisanobviousapplication,butsimultaneously
thebombardmentresultsinacrateredsurfaceformationinwhichlubricantsareretained.
Thisisofimportanceinanysituationwheretwometalsurfacesaremovinginrelationto
eachother.

The controlledhammeringeffectofshotpeeninghasbeenprovedtoclosetheporesof
metalsurfaces.Vacuumchambersneedtohaveanonporoussurfacetoreduceoutgassing

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duringpumpdownandglassbeadpeeningistheacknowledgedtreatment.Thetreatmentof
castings is another obvious area where the problem of porosity can be reduced. Surface
scratchesandmachiningmarksandsimilartinyimperfectionsactingasstressraisersarethe
causeofprematurefailureandtreatmentwithsphericalpeeiningmediacanremovethese
imperfections.Inmanyinstancesitisnecessarytorelievetensilestressinducedinthesurface
bygrindingorweldingduringmanufacture.Thesestressescanbemodifiedbypeeningthe
workpieceintheappropriateareas.

Treatmentbyglassbeadblastingisafasteffectiveandinexpensivemethodofburrremoval
which can be carried out in manually operated or fully automated plants. Where the
componentsaredesignedforusesunderstress,peeninganddebarringcanbeundertakenin
thesameoperation.

TheeffectofpeeningwhichcausestheAlmenstripstobendcanbeusedonmetalsheets
thathavetobeformedintoacurvedsurface.Bypeeningonesideonlyandatdifferent
intensitiesindifferentplaces,thesheetcanbeinducedtofollowacomplexcurve.Evenif
treatedononesideonly,bothsurfacelayerswillbeundercompressivestress,witharesultant
improved fatigue resistance. When peen forming it is possible to machine off the
microscopicallycrateredsurfacecausedbythepeeningaction,ifamachinedfinishisrequired.
The principle of peen forming can, of course, be applied to straightening deformed
componentsofthinsection.Comparedtomechanicalmethodsofstraightening,whichcan
producetensilestresses,theresultantcompressivesurfacelayercanbeoffbenefit.

Sofarnomentionhasbeenmadeofproductappearance.Thefinishthatresultfromglassbead
peeningcanbeapowerfulsalesfeature.Dependingonblastintensity,varyingfinishescanbe
obtained,fromasatinpearlreflectivesurfacetoapleasinghammereffect.

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