Albahit journal of applied sciences ISSN 2708-244X, e-ISSN 2708-8936, Vol.
3, Issue 1, 2022, 35-40
Analysis of Residual stresses induced by mechanical shot
peening processes using the X-ray diffraction technique and
finite element method of 2024-T351 Aluminum Alloy
Fareg Saeid Ali*1 , Aimen M Albakoush2 , Ali A Musbah3 , Abdussalam Ali Ahmed4
1&2
Department of Mechanical Engineering, College of Technical and Sciences Bani Walid, Libya.
3&4
Department of Mechanical Engineering, Bani Walid University.
*Corresponding author: faragpodina@yahoo.com
Abstract - Experimental validation and the dynamic three-
dimensions finite element simulation was utilized to examine
the residual stress relaxation that was developed using shot
peening in the 2024-T351 aluminium alloy deformed surface
layer. Experiments were conducted on specimens subjected to
three different shot peening intensities 4-6A, 6-8A and 8-10A
and tested under cyclic loading. The extent of the residual stress
redistribution during loading was investigated by X-ray
diffraction (XRD) measurements on plain specimens Numerical
methods which utilize finite element solvers simulate shot
peening media impacting a substrate surface and the resulting
plastic deformation The findings of the experiment
demonstrated the residual stress relaxation for the 170 MPa
load to be lower than the 280 MPa relaxation load for the 4-6A
shot peening intensity The 1st cycle’s maximum relaxation
reached more than 40% of the initial residual stress with highs
load and lower intensity. The minimum residual stress
relaxation among the three shot peening intensities was found
to be 33% of initial residual stress. This was under a given
applied load of 170 MPa and a shot peening intensity of 8-10A.
The results obtained from the numerical simulations,
correspond quite well with the experimentally result on shot
peened specimens.
Keywords: shot peening, fatigue, intensity, aluminum alloy,
residual stress.
I. INTRODUCTION
Manufacturing surface treatment processes introduce
residual stress into mechanical parts, which effects part's
fatigue behaviour [1]. In static loading, the true stress in a
component is determined by the residual and practical
stresses. If the static loading is compressive and increased
continuously, the residual stress delays the time needed to
reach the yield strength. However, it accelerates the time
needed to reach the yield strength in tensile loading
conditions. . In general, compressive residual stress increases
the usable material life by preventing the crack initiation and
propagation from occurring, whereas the tensile residual
stress reduces the material life by accelerating the crack
initiation and propagation of the components [2]. A residual
stress usually exists in different materials without the
presence of external stresses. There are many causes of
residual stresses, such as mechanical process, thermal
process, chemical processes and combined processes. One of
the known processes to improve fatigue life is to induce
residual stress by shot peening method which leads to a
compressive residual stress on the surface layer of metallic
components, making the crack initiation, growth and
propagation more difficult [3,4]. Other methods that can be
used to induce compressive residual stress may include
toughening of glass, cold expansion of holes and quenching
of materials [5]. Residual stress induced from shot peening
can be measured by different experimental techniques such
as X-ray, hole drilling, synchrotron, neutron diffraction,
ultrasonic etc. The common method used to measure residual
stress is X-ray diffraction (XRD). It is a non-destructive
method at the surface of specimens, and is applicable to
measure the most polycrystalline materials, metallic or
ceramic. The method does not significantly influence the
material properties such as cold work degree, hardness, or
preferred orientation. It is a linear-elastic process in which
the residual stress in the material is calculated from the strain
measured in the crystal lattice. The macroscopic residual
stress and the percentage of cold working can be obtained
simultaneously by XRD methods. There are basically two
methods of modelling the residual stress induced by shot
peening. The first one is through simulation analysis and the
second one is through empirical models depending on
experimental data. In empirical models, relaxation of the
residual stress layer induced by shot peening is observed
over the fatigue life. During fatigue cycles the residual stress
relaxation can be divided into stages: relaxation due to
surface yielding in the first cycle and gradual relaxation in
the following cycles. In these stages, residual stress decrease
significantly when compared to those with specimens with
no fatigue cycles [6,7].
II. LITERATURE REVIEW
One of the known process to improve fatigue resistance is by
using shot peening process [8, 9]. The main purpose of shot
peening is to induce compressive residual stresses to
improve fatigue properties at near the surface of material.
This is done by impacting a ductile metallic or ceramic
component repeatedly with a stream of small and hard shots
at high velocity. Numerous parameters of shot peening, such
as shot size, velocity, type, incidence angle, material
properties treatment, etc. have a great influence on the
surface of material treatment [10, 11]. There have been
numerous studies conducted to obtain the optimal shot
 Albahit journal of applied sciences ISSN 2708-244X, e-ISSN 2708-8936, Vol. 3, Issue 1, 2022, 35-40
parameters as well as understanding the effect of having
different materials as specimen. The effect of the velocity
relaxation and the mean shot velocity on the residual stress
depth relaxation was studied on 42CrMo4 [12]. It was
initiate that the depth of the layer with compressive residual
stress is improved by increasing shot velocity, while the
amount of maximum residual stress under the layer does not
depend on the mean shot rate. The compressive stress
amount is a function of the material properties of the target
specimen and the values maybe influence high as 50 to 60 %
of the tensile strength martial [13]. Shaw et al. [14] examined
the effects how residual stress variations can greatly
influence the bending fatigue performance measured on
carburized gears. The result from their work shows that
careful control of residual stress, through shot peening, can
bring up to a 75% increase in fatigue strength through the
introduction of high compressive residual stress. Residual
stress decrease on the surface of shot-peened specimens with
the cyclic load was measured using X-ray diffraction
technique. It was measured the experimental result by x-ray
diffraction and theses data its proposed by Kodama [15], the
relaxation of residual stress its following linear logarithm
relationship its large relaxation induced at initial few cycles.
III. EXPERIMENTAL METHODS
A. Materials
The fatigue specimens were prepared from 2024-T351
aluminum alloy with 6.5mm thickness plate as shown in
Figure1. This material has been selected for being the
standard alloy used to manufacture lower wing panels of the
actual generation of large commercial aircraft. This is one of
the best known of the high strength aluminum alloy. With its
high strength and excellent fatigue resistance, it is used to
provide advantage on structures and parts where good
strength-to-weight ratio is desired. This alloy is a solution of
heat-treated; control stretched and naturally aged material.
The raw material was received as a plate from Alcoa China
with a size 1 m, 1 m with 6.5 mm thickness, tensile strength
of 484 MPa, yield strength of 348 MPa and an elongation of
15%. The chemical compositions of the tested material are
given in Table I. The type of cutting machine used was
Mitsubishi RA9 CNC EDM wire cut machine, with diameter
of 0.25 mm and wire feed rate 1.1 m/min. The wire cut was
used to reduce the temperature generated during cutting
process, the cutting temperature was kept at range of (room
temperature) by using extensive cooling. The precision of the
machining was kept at ± 0.04mm.
TABLE I: SPECIFIC CHEMICAL COMPOSITION OF 2024-T351 AL ALLOY
(WT. %)
Component wt.% Component wt.%
Al 93.50 Fe 0.50
Cr 0.10 Mg 1.20-1.8
Cu 3.80-4.90 Mn 0.030-0.9
Ni 0.05 Pb 0.05
Si 0.50 Zn 0.25
Ti 0.15 Zr 0.20
Fig. 1. Specimen for fatigue testing (all dimensions in mm).
B. Shot Peening
To introduce residual stresses in the specimens, shot peening
as surface treatment was used. All specimens were shot
peened at GT Industrial PTE LTD; Singapore. The surface
flatness of specimens with close tolerance and verified. The
shot peening material treatment applied on surface of
specimen depends on a number of factors as size, velocity,
shape, angle, and flow rate. The specific steel used for
experimental calibration was SAE1070 cold rolled steel and
properties are shown Table II [16]. The relative work done
to the surface is called the penning intensity. To measure
peening intensity a standard strip called Alemen strip is used,
it is made from spring steel of carefully controlled quality to
a size within close tolerances. It is used in three thickness
called strips, the thickest strip is 2.38±0.02 mm and thinnest
strips is 1.30 ±0.02 mm. The curvature of the strip is
measured with the aid of a dial gauge after the strip is placed
and retained magnetically against two pairs of ball contacts
at a fixed distance apart. The gauge is zeroed with the
unpeened side towards the dial gauge stream and the Alemen
height is read directly in thousandths of an inch or
millimeters. An intensity range was selected since it is S110
cast steel shots to 4-6A, 6-8A and 8-10A Almen intensities.
The mechanical properties of shot peening material and
aluminum material as shown in Table II. A constant
specimen distance from the nozzle of around 120 mm was
maintained. Impact angle was 900 and surface coverage was
set to 200% and shots diameters were 0.356 mm for three
intensities. The velocities were set to 29 m/s, 42 m/s and 60
m/s for intensities 4-6A, 6-8A and 8-10A respectively. Shot
peening intensity was quantified by means of the
standardized Almen measurement.
TABLE II: MECHANICAL PROPERTIES OF SHOT PEEN AND SPECIMEN
MATERIAL.
Property of shot peen material Value
density of the steel shots S110 (ρs) 7872 kg/m3
Modulus of Elasticity (E) 201 GPa
Poisson’s ratio 0.29
Yield Strength (ρy) 495 MPa
Property of specimen material value
density (ρt) 2800 kg/ m3
elastic modulus (E) 210 GPa
Poisson’s ratio 0.31
Yield Strength (ρy) 379 MPa
 Albahit journal of applied sciences ISSN 2708-244X, e-ISSN 2708-8936, Vol. 3, Issue 1, 2022, 35-40

The 3D finite element model is used for the shot peened cut was used to reduce the temperature generated during
material and the fatigue analysis of 2024-T351 aluminium cutting process, the cutting temperature was kept at range of
alloy. Once the ANSYS Parametric Design Language (room temperature) by using extensive cooling. A
(APDL) code is useful for the 3D FEM to perform the fatigue thermometer was used to ensure that the temperature did not
analysis. Basically, the code is developed by combining exceed the temperature range. The precision of the
many of analytical solution to executed data of shot peening machining was kept at ± 0.04 mm. Constant amplitude of
to the finite element model in ANSYS Mechanical APDL sinusoidal loading with a frequency of 30 Hz was used at
There are a lot of formulas and equations related to residual room temperature in an Instron 8874 unit equipped with
stress are used in the shot peening code development and hydraulic grips. It is a fully-digital servo-hydraulic controller
apply it to the finite element model. The mesh format of 3D- that is able to provide an automatic calibration of all the
FEM is set-up to 6356 elements and 28762 nodes. compatible transducers. The test was carried out at ambient
temperature to ensure that failure due to any unwanted
mechanism would be avoided. Cyclic load of 1, 2, 10, 1000,
C. Residual Stress Measurement
10000 cycles were applied to the specimens for cover high
Residual stress of the specimens was measured by a two- and low load, for the three shot peening intensities.
angle sine squared- psi (Sin2 ψ) technique with a X-ray
diffraction meter equipped with Chromium Kα tube .This
was according to SAE HS- 784 that uses the diffraction of IV. RESULTS AND DISCUSSION
chromium K-alpha radiation from the (311) planes of the
The variation of residual stress with depth along the central
FCC structure of the 2024-T351 aluminium alloy. The Kα1
line for all the peening conditions of the target material. It is
peak is assumed to be located at precisely 159.0 degrees, and
possible to observe in that the greater the peening intensity,
the Kα1 and Kα2 wavelengths are assumed to be 2.28 and
the higher residual stress value to introduce the high depth of
2.293 ", respectively. The specimens were shocked during
compressive residual stress field. Moreover, the change of
range of ± 1.50 around the mean ψ angles through
the residual stress profiles with three different impact
measurement the residual stress intensity over more grains
velocities, in the X-direction (σx) and in the Y-direction (σy)
instruction to minimise the effect of the grain size.
in depth of the shot peened part after applied first cyclic load.
Diffractometer fixturing are parameters shown in Table III.
It is observed, here, that the residual stress depends on the
Moreover, previous the amount of the x-ray elastic constant
area and its absolute value is greater in the longitudinal (σx)
determination, which is needed for convert from the strain
direction than in the transversal (σy) direction as shown in
measured the macroscopic residual stress at normal to the
Table IV. These obtained results are in good agreement with
(311) planes of peened and unpeened 2024-T351 aluminum
those published in the literature [18, 19, 20].
alloy. During simulation, these top layers of the target
material was achieved within the top 500 microns. The
TABLE IV: INFLUENCE OF COMPRESSIVE RESIDUAL STRESS WITH DEPTH
element type used in this case is trigonal and 2D solid PEENED LAYER.
element property model is chosen for analyses. Mesh size Intensity 4-6 Intensity 6-8 Intensity 8-10
along curve was used to specify the element size and the Residual Depth Residual Depth Residual Depth
stress (mm) stress (mm) stress (mm)
spacing between them along the curve and the number of (MPa) MPa) (MPa)
element are 640 elements. -154.352 0 -173.19 0 -190.808 0
16.43599 0.71355 43.4910 0.71355 48.93744 0.71355
TABLE III: X-RAY DIFFRACTION RESIDUAL STRESS MEASUREMENT 0 97 54 97 93 9
PARAMETERS. 16.03643 0.72151 42.8098 0.72151 48.74579 0.72151
Item Condition 2 29 11 29 04 29
Incident beam 10.00520 0.86386 30.9523 0.86386 43.22877 0.86386
1.0 deg 7 18 07 18 39 18
divergence
Scintillation set for 90% acceptance of the 7.746925 0.93499 25.6340 0.93499 39.44799 0.93499
Detector: 1 84 74 84 99 84
chromium K-alpha energy
Power 25 kV and 25 mA 7.500659 0.94374 25.0189 0.94374 38.95542 0.94374
Psi rotation: 10.00 and 50.00° 0 81 86 81 25 81
Plane (Bragg Angle) (311) set of planes. (Bragg angle: 159°) 7.271522 0.95210 24.4399 0.95210 38.48069 0.95210
0.20in  0.20 in (5.1  5.1) mm
Irradiated Area 7 61 20 61 59 61
6.689753 0.97435 22.9392 0.97435 37.19953 0.97435
8 99 48 99 35 99
6.617647 0.97723 22.7501 0.97723 37.03272 0.97723
D. Fatigue Testing 5 02 02 02 46 02
The fatigue specimens were scaled on accordance with 6.457419 0.98370 22.3272 0.98370 36.65537 0.98370
6 39 33 39 9 39
airbus standard [17]. The size of the specimen is with 6.5
6.378537 0.98694 22.1177 0.98694 36.46615 0.98694
mm thickness as shown in Figure 1. The samples were cut 92 09 32 09 09
using low speed cutting progress. The cutting was performed 6.173860 0.99550 21.5700 0.99550 35.96419 0.99550
at SN Machinery services. The type of cutting machine used 99 10 02 10 0 10
6.162859 0.99596 21.5403 0.99596 35.93675 0.99596
was Mitsubishi RA9 CNC EDM wire cut machine, with 41 79 90 79 1 6
diameter of 0.25 mm and wire feed rate 1.1 m/min. The wire
 Albahit journal of applied sciences ISSN 2708-244X, e-ISSN 2708-8936, Vol. 3, Issue 1, 2022, 35-40
Figure 2 compares the resulting Uz (displacement in z
direction) field calculated from the finite element APDL
calculation for three velocities (800, 900, and 1000 in/sec).
The thickness of the shell element has been plotted for
illustration purposes. From Figure 2 it can be found that
highest velocity 25.4 m/sec (1000 in/sec) induces larger
displacement when compare with velocities 20.32 m/sec and
22.86 m/sec (800,900in/sec) in z direction for the same
peening parameters. In the static prebending analysis, all the
nodes on the shot were fixed. The nodes on the bottom
surface of the component with x = 0 were fixed in z direction
to prevent rigid movement. Figure 3 presents the Uz
(displacement in z direction) of nodes with y = 25.4 mm and
x = 200 mm after finite element calculation for three shot
peening velocities 20.32, 22.86 and 25.4 m/sec (800, 900 and
1000 in/sec). With these Uz displacement values, the
specimen heights fx, fy can be calculated directly for
different prebending moments. It can be found that residual
stress peened produces larger displacement when the apply
velocity 25.4 m/sec it was (0.945 mm) in x-direction when
compared with other velocities.
Fig. 2. The resulting Uz (displacement in z direction) field calculated from
FE calculation for different velocities (a) velocity 20.32 m/sec (b) velocity
22.86 m/sec (c) velocity 25.4 m/sec.
The influence of shot velocity on the residual stress
relaxation was investigated. The variations of shot velocities
its produce different compressive residual stress layer and
shot peening intensity (Almen intensity). However, the
maximum compressive residual stress layer induced by
highest velocity as shown in Figure 4. With increasing shot
impact velocity, the shot peening intensity (Alemen
intensity) and the depth of compressive residual stress zone
increased significantly. In experimental result it was
observed that for applied velocity of 29 m/s, 40 m/s, 60 m/s.
The shot peening intensity was 0.127 mmA, 0.178 mmA and
0.228 mmA respectively. Table IV summarizes these
simulated results for this specific shot peening case (shot
Intensities 4-6A, 6-8A and 8-10A, shot radius r= 0.35mm).
The depth displacement of longitudinal and transverse
residual stresses in the constrained strips shot peened with an
increasing number of passes are presented in Figure 3.
According to the presented material model the radius of the
flow surface is reduced with increasing accumulated plastic
strain and increasing residual stress amplitudes. Compared
with the experimentally determined curves the course of the
simulated compressive deformation is slightly more flat for
the small amplitude and is in good accordance with the
curves at the higher strain amplitudes.
Fig. 3. Uz displacements in the specimen following X directions with
different velocities shot peening.
Fig. 4. Shows simulation and experimental relationships between Almen
intensity and shot velocity for shot sizes S110 steel shots average diameter
of 0.356 mm and shot peening angles of 90o.
V. CONCLUSION
Stress relaxation takes place when the superposition of the
residual stresses and the applied stresses exceeds the yield
stress. The residual stress relaxation that took place during
the first loading cycle increased with the increase load
because of the quasi-static relaxation effects. Most of the
residual stress relaxations for the two applied stress (170
MPa and 280 MPa) were observed during the first cycle. It
was found that the relaxation for the stress of 280MPa was
 Albahit journal of applied sciences ISSN 2708-244X, e-ISSN 2708-8936, Vol. 3, Issue 1, 2022, 35-40

greater than the relaxation that occurred for the stress of
170MPa. For the first cycle load relaxation, the experimental
maximum relaxation was found to be 39% of the initial
residual stress that was measured after the first cycle, given
an applied load of 280 MPa and shot peening intensity of 4-
6A. After the first cycle, however, the minimum residual
stress relaxation among the three shot peening intensities
was found to be 33% of initial residual stress. This was under
a given applied load of 170 MPa and a shot peening intensity
of 8-10A.
In Proceedings of the International Conference on Mechanical Behavior of
Metals II, Society of Material Science, Kyoto. 1972.
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[18] Y. I. Nam, I. Jeong, B. C. Shin and J.-H. Byun, Enhancing surface layer
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surface methodology. Materials & Design, 2015. 83: p. 566-576.
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VI. ACKNOWLEDGMENT [20] B. Denkena, J. Köhler, B. Breidenstein and T. Mörke, Elementary

studies on the inducement and relaxation of residual stress. Procedia
The authors would like to thank Ministry of Higher Engineering, 2011. 19: p. 88-93.
Education of Libya, College Technical and Sciences \ Bani
Walid, and innovation and research centre (iRMC),
Universiti Tenaga Nasional Malaysia for the fund (UNIG-
2018 - J510050845).

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