Experimental and Numerical Study of Needle Peening Effects in Aluminium Alloy 2024-T3 Sheets

Peening of metallic components is an effective treatment used in aerospace and automotive applications to improve fatigue properties or to blend and repair localized damage. This process is typically carried out using metallic airborne media, called shot. However, different processes make use of different media, such is the case of hard, pneumatically powered needles of needle peening equipment. In order to obtain a better understanding of the effects of needle peening in the same context as shot peening, this research work had as an objective to study in detail the behavior of the needle peening equipment in order to characterize the process, design an experimental campaign to measure the effects of needle peening on AA2024-T3 and to develop and validate a Finite Element (FE) model capable of replicating the results of needle peening. The needle peening equipment prototype, called SPIKER R, was developed by Shockform Aeronautique Inc. The equipment was characterized by utilizing high-speed camera recording in order to study its behaviour by varying the operating pressure. The obtained collection of images was ran through a newly developed digital image algorithm, so as to quantify the needles' velocity and frequency. The impact velocity and impact frequency were determined for different equipment operating parameters. It was concluded that both the average impact velocity and the impact frequency increase as the pressure becomes larger. Behaviour anomalies among the different needles, such as frequency and velocity variations, were brought to light; these conclusions could be of interest to the manufacturer. Ideally, all of the needles should behave as similarly as possible so as to produce a more uniform process. The response to needle peening of AA2024-T3 in 1.6 mm thick sheet form was studied by needle peening test specimens with dimensions of an Almen strips using the SPIKER R. AA2024-T3 was selected since it was extensively studied at École Polytechnique de Montréal as part of previous shot peening research. Saturation tests were done to determine the deflection at saturation for different peening parameters. The specimen deflection was measured using the standard Almen gauge used as part of routinary process control. Due to the aluminium magnetic incompatibility with the Almen gauge, the deformed specimen profile was measured using a Coordinate Measuring Machine (CMM). Repeatability of the process was demonstrated and the deflection at saturation, as well as the saturation time, was obtained. The indentation diameters created by impacts for different operating pressures were measured using microscopic photography. It was determined that the specimen deformation, as well as the indentation diameter, is larger when the operating pressure increases.