Anti-Corrosion Methods and Materials

Surface stresses induced by grit blasting

S.S. Birley A. Owens
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To cite this document:
S.S. Birley A. Owens, (1979),"Surface stresses induced by grit blasting", Anti-Corrosion Methods and Materials, Vol. 26 Iss 7
pp. 5 - 7
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 July 1979 ANTI-CORROSION 5

Surface stresses induced by grit blasting

S. S. Birley, (Military Vehicles and Engineering Establishment, Chertsey), and

A. Owens, (Stress Engineering Services Ltd., Sheffield).

Summary Zn, 2.50%, Mg alloy. This note summarises the results of

Stress measurements using the blind hole drilling technique
with electrical resistance strain gauges have been made on
surfaces of an aluminium alloy which have been subjected
to a variety of grit blasting treatments. Relationships between
the induced stress and depth were determined for each treat­
ment. It is shown that the magnitude and the depth of the
induced compressive stress are particularly sensitive to varia­
tions in grit size and, to a much lesser extent, to changes in
the nozzle air pressure, the angle of impact and the duration
of the treatment.
Discussion of the results is centred on the need for control
of the operating variables in particular applications.
(c) Copyright H.MS.O. London 1979
1. Introduction
Grit blasting has a variety of specific applications generally
associated with surface cleaning or roughening—for example,
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these investigations and briefly discusses some of the
implications.
2. Grit blasting
The principal grit blasting variables examined were grit size
and nozzle air pressure. In addition, some assessment of the
treatment time and the impact angle of the grit was made.
Small coupons, 150mm x 150mm of 10mm thick plate of the
alloy were treated as shown in Table 1.
The dry treatments were carried out by Vacublast, Slough
and the wet treatments were carried out by Abrasive Deve­
lopments, Henley-in-Arden, using the Vaqua-D process.
The samples were generally treated until complete cover­
age, as judged by the operator, was just attained. Some
samples, however, were exposed for longer times.
The nozzle was generally inclined at 45° to the surface
normal, but in some cases, as stated in Table 1, impact angles
of 75° and 0° were assessed.

de-scaling, preparation for protective coatings or bonding,

and paint removal. There are also applications in which a
compressive stress is purposely induced into a surface to
provide, for example, some protection against fatigue or
stress corrosion. For many of the applications, it is not
necessary to control the process parameters, but clearly
there are some applications, particularly where it is intended
to introduce a specific level of compressive stress in a com­
ponent, or attain reproducibility between components, for
which the process parameters must be close controlled.
Recent work (1, 2, 3) carried out on the controlled shot
peening of Al-Zn-Mg plate edges suggested that grit blasting
could also induce a significant depth of compressive stress
at a treated surface. However, there is a general lack of
data on the depths of compressive surface layers and the
levels of compressive stress induced by grit blasting. This
resulted in the current work which attempts to assess the
effect of grit blasting variables on the magnitude and depth
of compressive stresses induced in surfaces of an Al, 4.75%
3. Stress measurement
There was a requirement to determine the stress-depth re­
lationship in the surface layer of each test coupon after
treatment. The use of the X-ray technique was considered
to be too time-consuming for determining the stress-depth
relationship. The most suitable method was the blind hole
drilling technique and electrical resistance strain gauges with
an incremental analysis(2). The conventional analysis(4) with
the blind hole drilling technique permits calculation of only
the magnitude of mean stress existing within a surface layer
with a thickness equal to the diameter of the drilled hole and
not the stress-depth relationship. The incremental analysis
fully described elsewhere (2) however allows the stress-depth
relationship to be determined quickly.
In the current work the hole drilled was 1.6mm diameter
and 1.6mm deep. For each of the experimental conditions,
the surface stress, the mean -stress and the stress-depth rela­
tionship were determined.

Surface Impact Angle Depth of

Alumina Air Pressure Coverage Roughness to Surface Surface Mean Stress Compressive
Grit Size (bar) Time Ra Normal Stress 0— 1.6mm. Stress
(secs) (μM) (degrees) (MPa) (MPa) (mm)
30/40* 5.8 28 7.3/8.4 45 -320 -49 >1.00
30/40* 4.3 28 7.6/9.1 0 -260 -45 >1.00
40/60 + 5.8 28 6.1/8.1 45 -240 -40 >1.00
40/60 + 4.3 28 5.6/6.6 45 -213 -27 >1.00
60/80+ 5.8 23 5.6/6.8 45 -200 -31 0.60
60/80 + 4.3 23 5.1/6.3 45 -136 -27 0.40
60/80+ 5.8 35 5.6/6.6 45 -180 -26 0.60
60/80 + 4.3 24 4.6/5.8 75 -125 -20 0.35
80/120 + 5.8 22 3.6/4.1 45 - 82 -12 0.40
80/120 + 4.3 22 3.6/4.1 45 - 74 - 9 0.30
80/120+ 4.3 23 3.2/4.1 75 - 64 - 8 0.25
80/120 + 4.3 30 3.6/4.1 45 - 78 - 9 0.30
180/120+ 5.8 20 2.7/2.5 45 - 10 - 3 0.25
180/220 + 4.3 20 2.3/2.5 45 - 9 - 3 0.20
180/220+ 4.3 25 2.3/2.5 45 - 6 - 3 0.20
180/220* 5.8 25 1.0/1.5 45 - 10 - 2 0.05
180/220* 4.3 25 1.0/1.5 45 - 10 - 2 0.05
*Wet Application. + D r y Application.
 6 ANTI-CORROSION July 1979

4. Results
The stress-depth curves for the different treatments are pre-
sented in Figures 1A and 1B representing blasting pressures
of 4.3 bar and 5.8 bar respectively. The mean stress and
surface values for each sample are presented in Table 1, and
summarised graphically, as a function of grit size in Figure
2. The surface roughness and depth of the compressive stress
layer are also given in Table 1.
The general observations are:
(1) The mean stress, surface stress and depth of compressive
surface layer all decrease with decreasing grit size and
air pressure for the range of variables examined.
(2) The depth of the compressive stress layer is particularly
dependent on the size of grit employed.
(3) There is a slight decrease of surface stress, mean stress
and depth of induced stress with increasing angle of
impact to the surface normal.
(4) The exposure time does not have much effect above
complete coverage.
(5) The method of application, wet or dry, does not have
much effect.
The above trends shown in the grit blasting work are
consistent with those obtained in previous work (1, 2, 3) for
shot peening of this alloy. The results confirm what one might
expect intuitively, but hitherto little attempt has been made
to ascribe values to the stress-depth relationship. It is pro-
bable that the observed stress levels and depths of compressive
surface layers merely reflect the degree of surface deforma-
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tion, which is, in turn to some extent indicated by the surface

roughness measurements. (In Table 1, note the surface
roughness, like the level and depth of compressive stress,
increases markedly with grit size and, to a lesser extent, air
pressure).

5. Discussion
Among the factors to be considered when deciding on a
particular grit blasting process are: —
(1) Whether a particular surface finish is required.
(2) Whether the stress distribution in the surface layer is
relevant.
In many instances the exact nature of the surface finish
is of paramount importance whereas the surface stress dis-
tribution is irrelevant. Some processes require a low degree
of surface uniformity whereas others may require a very
high degree of uniform finish, for example, as in the grit
blasting of some glasses and plastics.
The stress-depth distribution, alternatively, may be the
prime reason for the grit blasting treatment, and the surface
finish is merely a consequence of the residual surface stress
distribution induced.
From the above considerations of surface stress and surface
finish, it is clear that some applications require control of
the process parameters and others do not require much
control at all.
The current work demonstrates that if the process is not
controlled, treatment could result in a surface with a large
variation in the stress-depth relationship. This could be very
significant where the intention is specifically to introduce a
uniform surface layer of compressive stress. For example,
the surface may suffer from patchy corrosion, or premature
failure from fatigue or stress corrosion could occur in
susceptible alloys where there is an unusually high tensile
stress resulting from lack of control.
In instances where the surface stress distribution is of
prime importance, the major factor to be considered is the
size of grit, because this variable exerts the most influence
on the depth of the compressive stress layer required. Design
consideration must, however, be taken into account when
selecting the grit size. The depth of compressive stress re-
quired, which is predominantly determined by the grit size,
must be sufficient to resist any surface damage such as wear
 July 1979 ANTI-CORROSION 7

scouring or corrosion which might occur during service,

maintenance or repair.
Having selected the grit size, a small adjustment of the
other parameters will produce the required stress-depth dis-
tribution for the application in hand. Because it is cumber-
some to control all the operation parameters such as air
pressure, stand-off distance, impact angle and nozzle size
etc., actual control should be best achieved through the two
parameters Almen Intensity and Coverage. The Almen
Intensity is indicated by the Almen strip, and the coverage
is indicated by visual inspection. Coverage should be at least
100% on the required areas since lack of complete coverage
could be very deleterious to the component integrity eg.
small gaps in the treated surface could support very high
tensile stresses
The experimental determination of stress-depth curves
could be employed not only as the basis of the design of an
adequate grit blasting treatment, but for subsequent quality
control to check the success of the treatment. This need
only be done occasionally because the major check is achieved
through the Almen strip.
Similar treatments given to different alloys produce results
which are similar in trend, but different in magnitude. There-
fore if stress-depth curves are used to design a grit blasting
treatment, they are best determined on coupons of the actual
metal to be treated. Softer Al-Zn-Mg alloys will have a
lower value of compressive surface stress, but a greater
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coverage for a particular grit size with constant treatment

parameters'2'. For steel the levels of surface compressive
stress may be much higher and the depth of compressive
stress produced is not nearly so dependent on the indentor
size"'. In addition, there may be some danger from over-
treatment (i.e. extended coverage) particularly on high
strength steels due to the possible formation of small surface
cracks.
The results suggest that some measure of protection
against premature failure can be afforded by a controlled
grit blasting operation. The logical conclusion of this work
is that greater protection, particularly where wear is a con-
sideration, (where deeper compressive layers are required)
can be achieved by shot peening. This conclusion was in fact
confirmed by the work reported in reference 3. 8. Acknowledgements
6. Summary The assistance of Vacublast, Slough and of Abrasive
Stress-depth relationships for grit blasted Al, 4.75%, Zn, Developments, Henley-in-Arden is gratefully appreciated.
2.50%, Mg alloy surfaces have been determined, employing
the blind hole drilling technique with an incremental depth
analysis. It is shown that the induced surface compressive
stress, the depth of induced compressive stress and the induced
mean stress over the hole depth tend to increase with increas-
ing grit size, air pressure and decreasing obliquity of attack.
Grit size is particularly important in determining the depth
of the layer of compressive stress induced in aluminium
alloys.
The results imply that lack of control of the process may
in certain instances exert harmful effects on the integrity
of components.
7. References
1. R. G. Bathgate, B. A. Hatt, S. S. Birley
Welding Research International, Vol. 8. No. 4. pp. 316-
344, Nov. 1978.
2. S. S. Birley, D. Clarke, A. Owens
BSSM Conference, Bradford, Sept. 1978.
3 S. S. Birley, M. J. Morton, J. F. Alder
Conference "Residual Stresses in Welded Construction
and their Effects" Welding Institute, London, Nov.
1977.
4. E. M. Beaney, E. Procter
Strain Vol. 10. No. 1. pp. 7-14 Jan. 1974.
5. Private Communication
Metal Improvement Company, Derby, 1978.
 This article has been cited by:

1. N. MasmoudiDepartment of Mechanical Engineering, National School of Engineers of Sfax (ENIS), Sfax, Tunisia M.
KhlifDepartment of Mechanical Engineering, National School of Engineers of Sfax (ENIS), Sfax, Tunisia. 2012. Effect of blast
cleaning parameters on corrosion of brass parts. Multidiscipline Modeling in Materials and Structures 8:4, 454-468. [Abstract]
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