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Laser shock forging—a novel in situ method designed towards controlling residual stresses in laser metal deposition

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Abstract

This paper presents a novel hybrid in situ additive manufacturing (AM) method–laser shock forging (LSF), which combines laser shock peening (LSP) with laser melting deposition (LMD). Based on the classical bar-frame model and inherent strain theory, the mechanisms of the effects of pretreatment and posttreatment on AM process have been elaborated for the first time. Towards controlling tensile residual stress (TRS) in the as-built (AB) state of AM parts which has a detrimental effect on their fatigue life, we then developed LSF to introduce tensile inherent strains in LMD built parts in an in situ manner, which will convert TRS to compressive residual stress (CRS). The laser beam used for shock peening can be adjusted to move synchronously with the laser beam used for metal deposition and keep a certain distance, ensuring the laser shock peening to act on the region where the material temperature cools down to the forging temperature range. Then, experimental works have been conducted on 316L stainless steel; residual stress distributions of the AB, LSP, and LSF treated specimens were compared; results show that LSF increases both the magnitude and depth of CRS compared with conventional LSP treatment, thus providing a promising application in enhancing fatigue life in AM process.

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Funding

The presented investigations have been supported by the National Natural Science Foundation of China (No. 51775117) and Research and Demonstration of the Key Technologies for the Next-Generation Deep-Water Offshore Ultra-Large Wind Turbine Installation Platforms (No. 502200029). All the supports above are greatly acknowledged.

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Author notes

  1. Yongkang Zhang and Shupeng Cai contributed equally to this work.

Authors and Affiliations

  1. School of Electrical and Mechanical Engineering, Guangdong University of Technology, Waihuanxi Road 100, Guangzhou, 510006, China

    Yongkang Zhang, Shupeng Cai & Zhifan Yang

  2. COSCO Shipping (Qidong) Offshore Co., Ltd, No.1 Zhongyuan Road, Yinyang, 226006, Qidong, Jiangsu, China

    Ming Qiu & Zhengang Wang

  3. Keen Offshore Engineering Co., Ltd, Nanhai District, Lishui TownFoshan, 528200, China

    Pingping Wu

  4. Zhongtian Technology Group Co., Ltd, Nantong, 226010, Jiangsu, China

    Chi Xue

  5. Wuhan Marine Machinery Plant Co., Ltd, 9 WuDong Street, Wuhan, 430084, Qingshan, China

    Xiaojian Huo

Authors
  1. Yongkang Zhang
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  2. Shupeng Cai
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  4. Ming Qiu
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  7. Chi Xue
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  8. Xiaojian Huo
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Contributions

Yongkang Zhang: conceptualization; participation in the whole work; funding acquisition; and supervision; Shupeng Cai: participation in the whole work; writing of the article; data analysis and figure drawing; and revision of the manuscript; Zhifan Yang: data curation; Ming Qiu: development of equipment; Zhengang Wang: development of equipment; Pingping Wu: development of equipment; Chi Xue: development of equipment; Xiaojian Huo: development of equipment. All authors read and approved the final manuscript.

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Correspondence to Shupeng Cai.

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Zhang, Y., Cai, S., Yang, Z. et al. Laser shock forging—a novel in situ method designed towards controlling residual stresses in laser metal deposition. Int J Adv Manuf Technol 125, 2289–2304 (2023). https://doi.org/10.1007/s00170-023-10874-8

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