MIC Green Book

T A B L E O F C O N T E N T S
INTRODUCTION ............................................................. 3
CHAPTER 1:
THEORY
The Shot Peening Process........................................................................ 4
Shot Peening Residual Stress .................................................................. 5
Summation of Applied and Residual Stress ............................................. 6
Application Case Study: NASA Langley Crack Growth Study .................... 6
Depth of Residual Stress.......................................................................... 7
Shot Peening Media ................................................................................. 7
Effect of Shot Hardness............................................................................ 7
CHAPTER 2:
RESPONSE OF METALS
High Strength Steels ................................................................................ 8
Carburized Steels ..................................................................................... 9
Application Case Study: High Performance Crankshafts .......................... 9
Decarburization........................................................................................ 9
Application Case Study: Reduction of Retained Austenite...................... 10
Austempered Ductile Iron....................................................................... 10
Cast Iron................................................................................................. 10
Aluminum Alloys ..................................................................................... 11
Application Case Study: High Strength Aluminum .................................. 11
Titanium ................................................................................................. 12
Magnesium............................................................................................. 12
Powder Metallurgy ................................................................................. 12
Application Case Study: High Density Powder Metal Gears.................... 13
CHAPTER 3:
MANUFACTURING PROCESSES
Effect on Fatigue Life .............................................................................. 14
Welding .................................................................................................. 14
Application Case Study: Fatigue of Offshore Steel Structures ................ 15
Application Case Study: Turbine Engine HP Compressor Rotors ............ 15
Grinding ................................................................................................. 16
Plating .................................................................................................... 16
Anodizing ............................................................................................... 17
Application Case Study: Anodized Aluminum Rings............................... 17
Plasma Spray.......................................................................................... 17
Electro-Discharge Machining (EDM) ....................................................... 17
Electro-Chemical Machining (ECM)......................................................... 18
Application Case Study: Diaphragm Couplings ...................................... 18
CHAPTER 4:
BENDING FATIGUE
Bending Fatigue ..................................................................................... 19
Gears...................................................................................................... 19
Connecting Rods.................................................................................... 20
Crankshafts ............................................................................................ 21
Application Case Study: Diesel Engine Crankshafts ............................... 21
Application Case Study: Turbine Engine Disks ....................................... 21
CHAPTER 5:
TORSIONAL FATIGUE
Torsional Fatigue.................................................................................... 22
Compression Springs............................................................................. 22
Drive Shafts ........................................................................................... 23
Torsion Bars........................................................................................... 23
Application Case Study: Automotive Torsion Bars ................................. 23
CHAPTER 6:
AXIAL FATIGUE
Axial Fatigue .......................................................................................... 24
Application Case Study: Train Emergency Brake Pin.............................. 24
Application Case Study: Auxiliary Power Unit (APU) Exhaust Ducts....... 24
CHAPTER 7:
CONTACT FAILURE
Fretting Failure....................................................................................... 25
Application Case Study: Turbomachinery Blades and Buckets............... 25
Pitting .....................................................................................................25
Galling ................................................................................................... 26
CHAPTER 8:
CORROSION FAILURE
Corrosion Failure.................................................................................... 27
Stress Corrosion Cracking...................................................................... 27
Application Case Study: Fabrication of Chemical Handling Equipment .... 28
Corrosion Fatigue................................................................................... 28
Application Case Study: Sulfide Stress Cracking.................................... 28
Application Case Study: Medical Implants............................................. 29
Intergranular Corrosion.......................................................................... 29
CHAPTER 9:
THERMAL FATIGUE & HEAT EFFECTS
Effects of Heat ....................................................................................... 30
Thermal Fatigue...................................................................................... 31
Application Case Study: Feedwater Heaters ........................................... 31
CHAPTER 10:
OTHER APPLICATIONS
Peen Forming ......................................................................................... 32
Contour Correction................................................................................. 33
Work Hardening ..................................................................................... 33
Peentex sm ............................................................................................... 34
Engineered Surfaces .............................................................................. 34
Application Case Study: Pneumatic Conveyor Tubing............................ 35
Application Case Study: Food Industry .................................................. 35
Exfoliation Corrosion.............................................................................. 36
Porosity Sealing..................................................................................... 36
Internal Surfaces and Bores................................................................... 36
Dual (Intensity) Peening ........................................................................ 37
The C.A.S.E. sm Process ............................................................................ 38
On-Site Shot Peening............................................................................. 38
Strain Peening ....................................................................................... 39
CHAPTER 11:
CONTROLLING THE PROCESS
Controlling the Process.......................................................................... 40
Media Control ........................................................................................ 40
Intensity Control..................................................................................... 41
Coverage Control ................................................................................... 42
Automated Shot Peening Equipment ..................................................... 43
Application Case Study: CMSP Increases Turbine Engine Service Life ...... 44
Specifying Shot Peening ........................................................................ 45
CHAPTER 12:
ADDITIONAL CAPABILITIES & SERVICES
Peenstress sm – Residual Stress Modeling ............................................... 46
Laser Peening ........................................................................................ 46
Coating Services .................................................................................... 47
Heat Treating ......................................................................................... 48
Valve Reeds – Manufacturing................................................................. 48
APPENDIX:
Conversion Tables............................................................................. 50-51
MIC Technical Article Reprints.......................................................... 52-57
MIC Facilities Listing ........................................................................ 58-59
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