Shock Peening of engineering ceramics using

contact-less energy beams

Pratik P. Shukla
Advance Joining Centre, Coventry University, Coventry, United .Kingdom
Tel: +44 (0) 7739461805

Research Background
Laser Shot (Shock) Peening is a comparable process to the conventional shot peening
technique applied on various types of metal surfaces. Commercial advantages offered
by the laser systems such as flexibility, deep penetration (precise control of the thermal
input), shorter process times, high speeds, accuracy and aesthetics are attractive in
comparison with the conventional peening technique. Laser peening in the recent years
has developed and proven its success with steels, aluminium and titanium surfaces,
although, minimal research has been conducted on laser shock peening and
conventional shot peening of engineering ceramics [2, 4, 5]. The aim of this
investigation is to begin the process of addressing the gap in knowledge by applying
industrial lasers to hot pressed silicon nitride (HP Si3N4) in particular as a typical
engineering ceramic. This investigation is highlighted on the feasibility of shock
peening Si3N4 using contact-less energy beams such as industrial lasers and investigates
a change in the significant mechanical property; fracture toughness (K1c) of the Si3N4
ceramics. A 2 Kw pulsed Nd: YAG laser is used assisted by an industrial robot to
conduct experimentation on the HP Si3N4 ceramics.

1.0: Introduction
Applications of ceramics have been limited due to their crack sensitivity and low
fracture toughness (K1c), however, the use of ceramics have advanced over the years.
They are now considered as the new age material used to manufacture components for
the aerospace, automotive and military sectors. Engineering ceramics offer exceptional
mechanical properties, which allows them to replace the more conventional materials
currently used for high demanding applications. The mechanical property under
investigation was fracture toughness (K1c), since it is a very important property of any
material and especially ceramics in particular due to their brittle nature. Ceramics in
comparison with metal/ alloys have a low K1c, hence it would be an advantage if the K1c
of ceramics could be improved using a laser shock peening technique. This can open
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avenues for ceramics to be applicable to high demanding applications where metals/

alloys fail due to their low thermal resistivity, co- efficient of friction, wear rate and
hardness in comparison with ceramics.

In all cases a comparison was made with the characteristics of the conventional shot
peening process to assess the feasibility of surface treating engineering ceramics by the
aid of energy beams, to identify if a similar outcome is obtained to that of the
conventional mechanical technique [1].

2.0: Comparison of Systems

2.1: Constraints with Conventional Shot Peening

Changes in the surface topography

Deformation of the shots
Change of shot size requires machine set up
Shot diameter is only suitable for a specific type of nozzle
Recollection of shots
Shot peening control and processing intensity
Distortion

2.2: Rational for implementing contact-less shock peening

Penetrating depth of residual stress induced into the material
Improvement with surface roughness
No tool change require
No recollection of the fired shot
Availability of superior motion system and freedom of movement that aids
programming of complex shapes and geometries.
Feasibility for cooling the work-piece

2.3: Cost Summary

Cost of laser peening is high in comparison with the conventional shot peening systems.
However, laser peening is simply a superior process with controllable parameters
offering shorter process times. A small/medium size, brand new shot peening machine

Shock Peening of Engineering Ceramics Using Contact-less Energy Beams - Pratik Shukla
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could cost up to 30 K (GBP). In comparison, an average Nd: YAG or a CO2 high power
laser system (brand new) would cost up to 200 K to 250 K (GBP).

Laser Peening is an independent process, which means that it is performed after the
component has been manufactured. Most small medium size manufacturers do not
invest on laser peening systems for carrying out such a surface treatment. This is simply
because the laser systems are far too expensive to run and maintain just for the purpose
of a peening application.

The charges made by the job shops are purely dependant on the component size, shape,
geometry, weight quantity, ablative layer, area of peening (number of laser spots) and
the customer specification. Although, a typical hourly rate charged by a laser job shop
for shot peening a component such as large tubular welded heat exchanger can be
charged up to 75 (GBP) per hour. This included labour, machine set up and variable
costs such as electricity wear and tear of the equipment. The number of hours spent on
one particular job is again purely dependant on the features of the component. In
comparison with laser shock peening rates, the typical charges given for the mechanical
shot peening process was quoted up to 70 (GBP) which includes the machine set up
time. The reason for the cost of laser shock peening being higher than that of the
mechanical shot peening is due to the involved machine programming skills required by
the operator and also due to laser machinery comprising of more complexity during
operation.

3.0: Experimental Procedures

Sample size of 50mm x10mm x10 mm HP Si3N4 ceramics were used for the
experiments which were coloured with a thin layer of black ink to increase the laser
absorption. A 2 Kw pulsed Nd: YAG (Niodinium, Yitrium, Aluminium Garnet)
industrial laser was employed with a 1.06 µm wavelength, assisted by a KC-25 Kuka
industrial robot. To imitate the shot peening process, it is required that a top hat beam
was used so the output energy of the laser beam was distributed evenly on the surface of
the ceramic.

Shock Peening of Engineering Ceramics Using Contact-less Energy Beams - Pratik Shukla
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The Nd: YAG laser was comparable with the current industrial systems used for laser
shock peening/ hardening. A 3mm diameter spot was used for duration of 10 ms with
power densities ranging from 11 Kw/mm2 to 16 Kw/mm2. Argon was used as a
processing gas at pressures of 1 bar to minimise the effect of surface oxidation or a
possible change in the ceramics composition.

Figure 1: Nd:YAG Laser delivered by a fibre cable mounted on the KC-25 Kuka
robot during laser peening of Si3N4, placed on a holding fixture.

4.0: Summary of Results

Minimal effect on the ceramic was found below power densities of 11 Kw/mm2.

Thermal shocking resulted in the material fracturing when power densities up to

16 Kw/mm2 were induced. Power densities below this range displayed an
absence of cracking on the ceramic surface.

K1c of the ceramics was enhance by 19 % and was calculated as 7.12 MPa √m.
This was due to the softening of the top layer of the ceramic which reduced the
hardness leading to a significant increase in the ceramics K1c.

Over 35 % decrease in the materials surface hardness was found which resulted
in boosting the ceramics K1c. This indicated that the effect of laser shock peening
of metals/alloys is different to that of the engineering ceramics.

Shock Peening of Engineering Ceramics Using Contact-less Energy Beams - Pratik Shukla
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Surface roughness of the Nd:YAG laser peening was enhanced from 0.07 µm
(untreated surface) to 0.049 µm after the shock peening treatment which shows a
0.23 µm enhancement in the surface roughness after the shock peening treatment.

5.0: Summery
There are several constraints with the conventional shot peening process which open up
avenues for research work to be considered in this area. In order to gain any benefits
from the process, it is vital that the material surface yields mechanically and the process
of tensile stress is reversed so compression can be induced into the material. This is not
common with ceramics as they do not yield and plastically deform readily.

Existing constraints within the conventional shot peening process could be counteracted
if non-contact processes such as laser peening is implemented particularly with
ceramics. The cost of the laser systems is much higher in comparison with the
conventional shot peening process. However, laser peening is much superior to the
conventional shot peening due to the depth of the compressive residual stress obtainable
[2, 3, 4, 6]. Other reasons as previously discussed such as faster processing time,
flexibility with treating components of complex geometry and overcoming the
constraints existing by mechanical shot peening will attract large manufacturing
companies to implement such a system. However, SME’s (Small Medium size
Enterprises) will most likely revert to sub-contract the process to job shops.

Laser peening at the moment is only performed according to the customer demand and
component specifications, typically when the product demands deep induced residual
stress (automotive gears) for example. Engineers and designers have to make a choice
between processing cost and quality of treatment when choosing either laser peening or
the conventional shot peening process.

Processes such as laser peening have proved to be successful surface treatment methods
for metals and also generate further benefits compared to the more conventional
mechanical shot peening technique. This investigation proves a way forward with laser
shock peening of ceramics from the view point of gaining the better from brittle

Shock Peening of Engineering Ceramics Using Contact-less Energy Beams - Pratik Shukla
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materials such as ceramics. Further work is ongoing with regards to the current findings
and the behaviour of the ceramics during pulsed laser beam interaction.

Further results presenting the justification of the current finding (in depth), along
with the laser beam material interaction during the laser shock peening treatment of
Si3N4 ceramics are justified in the technical paper.

6.0: References
1. Verpoort, C. Gerdes, C. (1989) ‘Influence of Shot Peening on material
properties and the controlled shot peening of turbine blades’. Metal behaviour
and surface engineering IITT international n. Vol , n. p

2. Hackel, L. (2005) ‘Shaping the future-laser peening technology has come of

age’. Metal Improvement Company Ltd Vol 19, (Issue 3) n. pp

3. Clauer, A. (1996) ‘Laser Shock Peening for fatigue resistance in surface

treatment of titanium alloys’. The metal society of AIME conference n. vol, pp 1-
14 [online] available from <http://www.stellarwind.com/LSPT/pub1014.pdf> [c.
2006]

4. Solomah, A. Mannik, A. Brown, S. (1993) ‘Laser Machining of Silicon Nitride

Ceramics’. Proceedings of the international conference on machining of
advanced materials n. vol, n. pp

5. Pfeiffer. Frey, W. (2002) ‘Shaping the future- damage or benefits’. Fraunhofer

Institute for mechanics of materials ICSP-8, Germany

6. Specht, R. Harris, F. (2002) ‘Process Control Technique for laser peening of

metals.’ 6th European conference on residual stress, p1-6

This research was conducted by Pratik Shukla working as a research student for the
degree of MSc by research at the Centre for Advance Joining (Coventry University,
United Kingdom), under the supervision of Dr Colin Page, 2006- 2009.

Shock Peening of Engineering Ceramics Using Contact-less Energy Beams - Pratik Shukla