Effect of Surface Nanostructure On Tensile and Low Cycle Fatigue Behavior of Al 2014 Alloy

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Effect of surface nanostructure on tensile and low cycle fatigue behavior of Al 2014 alloy
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2014 IOP Conf. Ser.: Mater. Sci. Eng. 63 012017
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6th International Conference on Nanomaterials by Severe Plastic Deformation IOP Publishing
IOP Conf. Series: Materials Science and Engineering 63 (2014) 012017 doi:10.1088/1757-899X/63/1/012017
Effect of surface nanostructure on tensile and low cycle

fatigue behavior of Al 2014 alloy
K Chattopadhyay*, V Pandey, N C S Srinivas, V Singh
Department of Metallurgical Engineering, Indian Institute of Technology

(Banaras Hindu University), 221005 Varanasi, India.
*E-mail address: kausik.met@iitbhu.ac.in
Abstract. Aluminium alloy 2014 is an important age hardening alloy for aerospace
industries. Effect of ultrasonic shot peening (USSP) in peak aged condition of this alloy
was studied on its surface microstructure, tensile properties and low cycle fatigue
behavior. The structure of the USSP treated specimens, close to surface was characterized
by X-ray diffraction and transmission electron microscopy. The top surface region was
found to contain nanosize grains of ~30 nm. Both yield as well as tensile strength was
found to increase progressively with increasing duration of shot peening for 10, 15 and 20
minutes. LCF behavior was studied following ultrasonic shot peening for 10 minutes, at
three total strain amplitudes (∆εt/2) of ±0.4%, ±0.5% and ±0.6%.
Keywords: 2014 aluminium alloy, ultrasonic shot peening, surface

nanocrystallization, low cycle fatigue.
1. Introduction
Aluminium alloy 2014 is an important age hardening alloy and is extensively used in aircraft
industries because of its high specific strength. However, there is much scope of improvement
in its fatigue resistance.
It is well established that fatigue, fretting fatigue, wear and corrosion are highly sensitive
to structure and properties of surface of the components and in most cases failures originate
from surface. Optimization of structure and properties of surface may effectively enhance
service life of structural components. Introduction of compressive residual stress and presence
of nanostructure at surface is known to increase fatigue life of structural metallic components.
Last few decades have seen considerable scientific interest in ultrafine-grained materials,
especially nanocrystalline (NC), with size up to 100 nm [1-6]. Nanostructuring at the surface is
known to enhance fatigue resistance without any modification in the chemical compositions and
shape of the components [7].
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
Ultrafine-grained structures have been achieved by severe plastic deformation (SPD)

through imposition of intense plastic strains. The microstructure resulting from severe plastic
deformation is substantially reduced in grain size, and associated with high internal stresses
along with high-energy non equilibrium boundaries [8].The requisite high plastic strain of the
order of several hundreds of percent can be produced by various available techniques, such as
equal-channel angular pressing (ECAP) [9-11], high-pressure torsion [12] , sliding wear [13,14],
ball milling [15,16], shot blasting [17,18], ultrasonic shot peening [19-24] and air blast shot
peening [25,26]. Ultrasonic shot peening (USSP) is considered to be an effective means of
surface grain refinement through severe plastic deformation of surface to nanosize. In USSP,
there is bombardment of surface of work piece with metallic projectile balls, to create a layer of
severe plastic deformation at the surface. During the process of USSP, ultrafine grain structures
are produced due to intense strain and high strain rates in the surface region. These intense
strains give rise to strain gradient in the surface region, varying from a maximum at the top
surface to zero at some depth in the matrix [12]. Higher intensity shot peening increases the
depth of compressed region by virtue of increasing the duration of shot bombardment, peening
with larger balls or at higher amplitude, or both. Increase in shot peening intensity, however,
increases roughness of the surface and the level of cold work at the surface, both of which are
known to reduce fatigue performance [26].
The recent work of Abood et al. [27] on AA 2024-T4 has revealed that its tensile and
yield strength increased due to shot peening and attained highest value at 15 minutes of shot
peening. Longer peening caused decline in strength. LCF tests showed that increase in shot
peening duration led to reduction in transition fatigue life (NT), till 15 minutes of peening.
Curtis et al. [28] made two propositions; resistance to development of crack tip plasticity
increased by work hardening of the peened layer and resistance to crack opening or closure of
crack increased by the compressive residual stress. Luong et al. [29] used two techniques,
namely shot peening and laser peening on 7050-T7451 and reported that out of the two
techniques, laser peening induced a layer of compressive residual stress more than three times
deeper than that from shot peening , though both the treatments were found to increase the
fatigue performance significantly. However, limited research is available on the effect of
ultrasonic shot peening on low cycle fatigue behavior of 2014 aluminium alloy.
The objective of the present investigation was to study the effect of ultrasonic shot
peening (USSP) on microstructure in surface region, tensile properties and LCF behavior of the
precipitation hardened 2014 aluminium alloy. The material was tested for the above
characteristics both in peak aged (175°C for 8 hrs) as well as peak aged and shot peened
condition.
2
2. Materials and Methods
The nominal chemical composition the 2014 aluminium alloy used in the present investigation
was determined by spark emission spectrometer and is presented in Table 1. The material was
solution treated at 500°C for 2 hrs, quenched in water and subjected to peak ageing at 175°C
for 8 hrs and cooled in air.
Table 1 Chemical Composition of the aluminium alloy 2014 (wt%)
Cu Mg Mn Si Fe Cr Zn Al
Wt% 4.38 0.45 0.51 0.54 0.29 0.004 0.03 Bal.
Disks of 5 mm thickness and 23 mm diameter were used for USSP by SONATS Stress Voyager in
order to characterize the microstructural modification using transmission electron microscopy.
Ultrasonic shot-peening treatment of the alloy 2014 was performed with steel balls of 3mm
diameter at amplitude of 80 µm for different lengths of time (Table 2).
Table 2 Effect of USSP treatments on Microhardness and Depth of modified layer

S. No. Ball size Amplitude Peening time Microhardness at Depth of
(mm) (µm) (min) surface (Hv) modified layer
(µm)
1 10 258 962
2 3 80 15 261 686
Optical metallography of the specimens in solutionized and peak aged condition was carried
out following mechanical polishing and etching with a solution of 95 ml H2O, 2.5 ml HNO3, 1.5
ml HCl and 1.0 ml HF at room temperature. Microstructure was examined using image
analyzer. Microhardness was measured using Shimadzu micro hardness tester at applied load
of 100g and dwell time of 5 seconds. TEM foils of the USSP treated surface layer were prepared
by cutting a thin slice near the shot peened region and subsequently electro chemical polishing
using an electrolyte of 20% nitric acid in methanol at -30°C at applied voltage of 22V.
Transmission electron microscopic (TEM) examinations were carried out on a TECNAI 20 G2
transmission electron microscope operating at 200 kV. A Rigaku X-ray diffractometer with Cu
Kα radiation was used to determine phase constitution and mean grain size at room
temperature in the shot peened condition. Crystallographic structure of the USSP treated
samples was characterized by XRD in the 2ϴ range from 20° to 80°. The grain size was
calculated from line broadening of Bragg diffraction peaks using Scherrer and Wilson Method
[30].
3
Tensile properties were determined using a 100 kN screw-driven InstronTM (Model

4206) universal testing machine, at a strain rate of 5×10-3 s−1, at room temperature. All the
tensile test specimens were prepared with gage length and diameter of 15.4 mm and 4.5 mm
respectively.
LCF tests were conducted on a servo hydraulic MTSTM of 50 kN (Model 810) under total
strain control mode with triangular wave form and fully reversed axial loading (R = -1 ), at
different strain amplitudes. Cylindrical LCF test specimens with threaded ends of 30 mm length
and 12 mm diameter, gage section of 15 mm length and 5.5 mm diameter and shoulder radii of
25 mm were machined from the heat-treated blanks.
3. Results and Discussion
3.1 Microstructure
Figs. 1 (a) and (b) show optical microstructures of the alloy in solution treated and peak aged
condition (175°C for 8 hours) respectively.
a b
Figure 1 Optical micrographs of the 2014 aluminium alloy (a) solutionized condition (b) peak aged
condition
Two different types of intermetallic particles, CuAl2 with white outlined structure and dark
complex compound of Al12(Fe,Mn)3Si may be seen. Dispersoids and coarse precipitates are
known to cause highly heterogeneous deformation and consequent damage to fatigue
resistance [31, 32]. It may be seen that in the solution treated condition the amount of
dispersoids was less as compared to that in the peak aged condition. The average grain size of
the solutionized and peak aged samples was found to be 76 µm and 92 µm respectively.
4
3.2 Effect of Ultrasonic Shot Peening:
3.2.1 Microstructure
Fig. 2 shows X-ray diffraction (XRD) profiles of solutionized samples subjected to different
durations of shot peening.
Figure 2 XRD profiles of 2014 aluminium alloy in solutionized and peak aged condition and shot peened
for different durations.
It is obvious from XRD profile that there was no phase transformation in surface layer of
the alloy 2014 from USSP treatment. However, the Bragg diffraction peaks after USSP
treatment became broader than those of the original sample, suggesting grain refinement
and/or an increase in the atomic level lattice strain [33, 34]. With increase in USSP time the
intensity of peaks decreased revealing slight change in average grain size in the top surface
layer. It may be seen that as the duration of shot peening time increased Bragg peaks broadened
and the grain size was reduced.
Fig. 3 show TEM micrographs of surface region of the samples shot peened for 10 mins.
It can be seen that nanocrystalline grains were formed after shot peening treatment and were
mostly equiaxed with random crystallographic orientations same as observed by Blonde et.al on
Cu [35]. The average grain size measured from bright field micrographs was found to be ~30
nm for the samples treated for 10 min whereas for un-shot peened specimen it is in the range of
10-600 nm [36] .
5
Figure 3 Bright Field TEM micrograph and corresponding SAD pattern: (a) 10 minutes of USSP
treatment (b) Corresponding SAD pattern
The SAD pattern showed formation of discontinuous ring pattern and confirmed drastic
grain refinement and formation of nanosized grains. The SAD pattern showed partially
developed circle with well-defined diffraction spots, indicating microbands consisting of low
angle misorientations [12]. The subsequent shot peening results into annihilation or
rearrangement of a large number of dislocations, to form small angle grain boundaries
separating individual grains. Formation of nanocrystalline structure in the surface layer due to
ultrasonic shot peening treatment had its familiarity with the process of nanostructuring by
severe plastic deformation of metals and alloys, involving generation of repeated
multidirectional mechanical loads at high speeds onto the surface of the material. Further,
USSP resulted into formation of crystallites with completely random orientation.
3.2.2 Microhardness
The variation of microhardness in transverse section of the shot peened specimen, from surface
towards interior, is shown in Fig. 4. Microhardness of the top surface increased with increase in
shotpeening time and the effectiveness of shot peening also increased to larger depth from the
surface and it gradually decreased with increase in distance from the surface towards interior.
6
Figure 4 Variation of microhardness with depth from the surface in longitudinal section of USSP treated
sample of the solutionized 2014 aluminium alloy, for different durations of peening.
The hardness of the unshotpeened sample was 181 VHN and that of shotpeened sample
was reduced significantly from top surface to the depth of about 500 µm. It is conventional that
effect of USSP treatment on the hardness profile was limited to a depth of ~500 µm. Increase in
microhardness at surface was from refinement of microstructure
microstructure resulting from shot peening by
hard balls and formation of porosity free highly dense nanocrystallized surface layer. Thus, the
material after USSP treatment unveiled better mechanical properties. The increase in grain size
with increase in depth from the peened surface is in li ne with earlier observations [37, 38].
line
3.2.3 Tensile properties
It is evident from Fig.5 that yield strength (σy) and tensile strength (σu) increased with duration
of shot peening upto 15 minutes and declined with further increase in peening time. The yield
strength was 469 MPa with ~13% increment. Tensile strength increased to 531 MPa which was
~9% higher than to that of the un-shotpeened specimen. Ductility decreased from 17% to 11%
with increase in time of shot peening upto 20 minutes.
7
530 531 521

483
469 467
600 410 417
500
400
300
200 Tensile Strength
100 17 13 12 11 Yield Strength
Total Elongation
0
PA PA+USSP PA+USSP PA+USSP
10 mins 15 mins 20 mins
Figure 5 Variation of yield & tensile strength and total elongation with peening time.
The engineering stress-plastic strain curves and the log-log plots of the true stress vs
true plastic strain are depicted in Figs.6 (a) and (b) respectively.
(a)
8
(b)
Figure 6 (a) Engineering stress-engineering plastic strain curves (b) True stress-plastic strain plots on log
log scale for different conditions of the alloy 2014.
The best combination of ultimate tensile strength and yield strength with adequate
ductility was exhibited by the specimen shot peened for 15 mins. The degree of work hardening
was highest in the peak aged specimen followed by USSP treated samples for 10 mins, 20 mins
and 15 mins respectively. Tensile data of the as received and different shot peened specimens
was analyzed using Hollomon relationship, σ = Kεnp, [39] where K and n are the strength
coefficient and strain hardening exponent respectively. Work-Hardening parameters for the
different conditions are listed in Table 3.
Table 3 Work-hardening parameters of the 2014 Aluminium alloy in different conditions

S. No. Designation K (MPa) n
1 PA 702 0.11
2 PA+USSP 10mins 635 0.06
The n value of the shotpeened sample was found to be much smaller than that of the
unshotpeened one. The surface roughness of un-shot peened tensile specimen was measured
and found to be 0.192 µm whereas value of surface roughness for the USSP sample treated for
9
10 mins, 15 mins and 20 mins was 2.463 µm, 2.895 µm and 3.455 µm respectively. Roland et al.
[34] also observed enhancement in tensile properties of 316L stainless steel from SMAT
processing. As reported earlier by Xing et al. [40] increase in strength could be due to strain-
induced nanostructured layer which enhanced strength and rigidity of the surface so that the
initiation of cracks and defects was reduced, in addition formation of slip bands was inhibited
due to nanostructured surface. The decrement in values of σu and σy of the samples, shotpeened
for more than 15 minutes, may be due to increase in surface roughness which was more effective
than the compressive residual stresses. This observation is similar to that made by Abood et al.
[27] in aluminium alloy 2024-T4 and signifies the role of surface roughness on loss of
properties. The value of strain hardening exponent (n) also decreased with increase in peening
time indicating loss of work hardening due to very low dislocation storage efficiency inside tiny
grains of the refined microstructure [41].
3.2.4 Low Cycle Fatigue behavior
Cyclic stress response curves of the peak aged and peak aged ultrasonic shot peened
specimen for 10 minutes are shown in Fig. 7 at different total strain amplitudes.
10
Figure 7 Cyclic stress response curves of the 2014 aluminium alloy at different strain amplitudes: (a)
peak aged (b) peak aged & ultrasonic shotpeened.
It may be seen that there was mild cyclic hardening up to 200 cycles both in the peak
aged as well as in the peak aged-USSP sample, at all the strain amplitudes and it was followed by
near stabilization till failure, except in the case of peak aged condition, in which cyclic hardening
was observed before failure.
Fatigue life of the aluminium alloy 2014 in PA and PA+USSP condition at the three
strain amplitudes are recorded in Table 4.
Table 4 LCF data of the 2014 aluminium alloy in different conditions

Total strain Fatigue life, Nf (cycles) Rate of crack propagation
amplitude, (∆εt/2) (µm/cycle)
PA PA+USSP PA PA+USSP
±0.4% 9235 35121 1.34 0.706
±0.5% 4089 8785 2.18 2.05
±0.6% 800 1405 2.43 1.57
It may be seen that there was substantial increase in fatigue life due to shot peening. Fatigue life
was increased by 75%, 115% and 280% for the samples tested at strain amplitudes of ±0.6%,
±0.5% and ±0.4% respectively in comparison to that of the un-shotpeened samples. The USSP
treatment is seen to be an effective means of enhancing fatigue life of the 2014 aluminium alloy,
in particular at the low strain amplitudes. The enhancement in fatigue life due to USSP
treatment was found to increase significantly with decrease in strain amplitude.
11
The dependence of fatigue life on strain amplitude was analyzed using the Coffin–Manson
relationship [38] between the plastic strain amplitude (∆εp/2) and number of reversals to
failure (2Nf).
∆εp/2 =εf'(2Nf)c
Figure 8 Variation of fatigue life with Plastic strain amplitude
Where εf' and c are fatigue ductility coefficient and exponent respectively. A linear variation was
observed in the plot of ∆εp/2 vs 2Nf (Fig. 8). It may be seen that fatigue life of the shot peened
samples was progressively higher than those of the un-shot peened samples with decrease in
strain amplitude.
The cyclic hardening observed during the initial 150 to 200 cycles at all the strain
amplitudes, both in the peak aged as well as in peak aged+USSP condition, could be attributed
to increase in dislocation density and increasing degree of dislocation-dislocation interaction as
well as interactions with the dispersoid particles and strengthening precipitates [42, 43]. This
effect was more pronounced at higher strain amplitudes.
Considerable improvement in fatigue life of the shot peened samples was observed at all
the strain amplitudes of ±0.40%, ±0.50% and ±0.60%. However, the improvement in fatigue
life was highest at the lowest strain amplitude of ±0.4% as compared to that at higher strain
amplitudes of ±0.5% and ±0.6%. The increase in fatigue life occurred due to two phenomena,
12
one from delay in the process of crack initiation because of compressive surface residual
stresses which reduced the effective tensile stress and the other was from slower crack growth
due to subsurface tensile stresses [29]. Thus, localized plastic deformation in the surface region
caused refinement of the microstructure and induced compressive residual stress in the surface
layer to resist fatigue crack initiation.
5. Conclusions
Following conclusions may be drawn from the present investigation:
• A layer of nanostructure was formed on the top surface containing nanocrystalline

grains of ~30 nm size.
• The USSP process effectively induced surface nanocrystallization in the aluminium alloy
2014.
• Microhardness at the surface increased with peening time and decreased with depth
from surface towards interior up to a depth of 500 µm.
• There was no phase transformation due to ultrasonic shot peening.
• Maximum value of tensile stress and yield stress (σu and σy) for the alloy 2014 was
observed in samples peak aged and treated by USSP for 15mins.
• There was significant increase in fatigue life due to USSP. Fatigue life of USSP samples
increased progressively with decrease in strain amplitude.
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16

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Home Search Collections Journals About Contact us My IOPscience

2014 IOP Conf. Ser.: Mater. Sci. Eng. 63 012017

Please note that terms and conditions apply.

Effect of surface nanostructure on tensile and low cycle

K Chattopadhyay*, V Pandey, N C S Srinivas, V Singh

Department of Metallurgical Engineering, Indian Institute of Technology

Keywords: 2014 aluminium alloy, ultrasonic shot peening, surface

Ultrafine-grained structures have been achieved by severe plastic deformation (SPD)

2. Materials and Methods

Table 2 Effect of USSP treatments on Microhardness and Depth of modified layer

Tensile properties were determined using a 100 kN screw-driven InstronTM (Model

3. Results and Discussion

3.2 Effect of Ultrasonic Shot Peening:

3.2.3 Tensile properties

530 531 521

Table 3 Work-hardening parameters of the 2014 Aluminium alloy in different conditions

3.2.4 Low Cycle Fatigue behavior

Table 4 LCF data of the 2014 aluminium alloy in different conditions

Figure 8 Variation of fatigue life with Plastic strain amplitude

Following conclusions may be drawn from the present investigation:

• A layer of nanostructure was formed on the top surface containing nanocrystalline

[1] Birringer R, Gleiter H, Klein H, Marquardt P. Nanocrystalline Materials an Approach to a

[3] Bohn R, Haubold T, Birringer R, Gleiter H. Nanocrystalline intermetallic compounds—An

[6] Kulik T. Nanocrystallization of metallic glasses. Journal of Non-crystalline Solids (2001);

[23] Guo FA, Trannoy N, Lu J. Analysis of thermal properties by scanning thermal

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