目的 为实现兼顾表面完整性与深层强化的喷丸效果。方法 以55CrSi弹簧钢为研究对象,在常规喷丸（SP）基础上,引入超细粒径、高比重钨颗粒作为喷丸介质,实施多道次钨颗粒喷丸（Tungsten particle shot peening, TPSP）工艺。通过表面形貌、EBSD、残余应力、显微硬度及三点弯曲疲劳试验,系统分析不同喷丸工艺对材料的强化效果。结果 与常规喷丸相比,二道次TPSP处理可显著改善试样表面完整性,表面粗糙度明显降低,稳定在约2.25 μm。随着TPSP处理道次的增加,试样表层塑性变形层厚度逐步加深,最大可达约30 μm,并在ND方向形成显著的〈001〉择优取向。同时,表层核平均取向差（KAM）明显提高,小角度晶界比例增至37.9%。经过二道次TPSP处理后,在距离样品表面70 μm处获得最大残余应力,达到约-963.7 MPa;样品次表层硬度提高至725HV,平均晶粒尺寸细化至0.49 μm,得益于优良的表面完整性与深层强化效果的协同作用,样品疲劳寿命达到5.44×104次,较SP处理提高82%。结论 二道次钨颗粒复合喷丸工艺在显著改善表面完整性的同时,实现了深层强化,二者的协同效应显著提升了55CrSi弹簧钢的疲劳性能。
Abstract
Fine particle shot peening is an advanced surface strengthening technique in which fine shots with particle sizes ranging from 20 to 200 μm are accelerated by high-pressure air to impact the workpiece surface at high velocity. This process introduces a stable compressive residual stress layer in the near-surface region while effectively suppressing excessive surface damage, thereby ensuring good surface integrity. Owing to its high strength, excellent elastic recovery and superior fatigue resistance, 55CrSi spring steel is widely used in critical load-bearing components such as automotive suspension springs. To further enhance the fatigue performance of spring steel through the synergistic optimization of surface integrity and subsurface strengthening, 55CrSi spring steel is selected as the research material. The samples are first treated by conventional shot peening (SP) using cut steel wire shots with a diameter of 0.8 mm and a hardness of 670 HV at an Almen intensity of 0.645 mmA. Subsequently, a multi-pass tungsten particle shot peening (TPSP) process is applied on the basis of SP. Ultrafine tungsten particles with diameters of 50-150 μm and a high density of 19.0 g/cm3 are employed as the peening media, with the peening pressure maintained at 0.6 MPa. The effects of different shot peening processes on surface integrity, microstructural evolution, mechanical properties, and fatigue behaviors are systematically investigated by surface morphology characterization, electron backscatter diffraction (EBSD), residual stress measurements, microhardness testing, and three-point bending fatigue experiments. The results indicate that, compared with conventional shot peening, two-pass TPSP treatment leads to a pronounced improvement in surface integrity. The surface profile height variation is effectively reduced, with the peak-to-valley height difference along the x-direction decreasing to 22.18 μm. Meanwhile, the surface roughness is markedly reduced and stabilized at approximately 2.25 μm, demonstrating effective suppression of surface damage. With increasing TPSP passes, the thickness of the plastically deformed surface layer gradually increases, reaching approximately 30 μm. EBSD analysis reveals the formation of a strong ⟨001⟩ preferred crystallographic orientation along the normal direction (ND). In addition, the kernel average misorientation (KAM) in the near-surface region increases notably, and the fraction of low-angle grain boundaries rises to 37.9%, indicating enhanced dislocation accumulation and intensified plastic deformation. After two-pass TPSP treatment, the compressive residual stress layer is significantly deepened, with the maximum compressive residual stress reaching approximately -963.7 MPa at a depth of about 70 μm below the surface. At a depth of approximately 10 μm, the microhardness is increased to 725HV, representing an improvement of 39% compared with the SP-treated sample. A continuous hardened layer with a thickness of approximately 80 μm is formed. Meanwhile, the surface grains are refined to 0.49 μm, and a pronounced fine-grained layer is obtained. Benefiting from the combined effects of improved surface integrity and enhanced subsurface strengthening, the fatigue life increases to 5.44×104 cycles, corresponding to an 82% improvement over that of conventionally shot-peened samples. Fractographic analysis further indicates that, after TPSP treatment, the fatigue crack initiation behavior changes from multiple crack origins to a single dominant crack origin. This transition suggests that the improved surface integrity and reduced stress concentration effectively suppress the formation of premature microcracks at the surface, thereby delaying crack initiation under cyclic loading. In addition, the presence of a deep and stable compressive residual stress field, together with the enhanced subsurface hardness, contributes to the retardation of crack propagation during the early stages of fatigue damage. Overall, the two-pass tungsten particle composite shot peening process effectively improves surface quality while achieving deep-layer strengthening, and its multiscale synergistic strengthening mechanism plays a critical role in enhancing the fatigue performance of 55CrSi spring steel.
关键词
弹簧钢 /
复合喷丸 /
钨颗粒 /
表面完整性 /
疲劳性能 /
残余应力
Key words
spring steel /
compound shot peening /
tungsten particles /
surface integrity /
fatigue performance /
residual stress
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基金
山东省自然科学基金（ZR2022ME210）; 山东省精密制造与非传统加工重点实验室（202201009）
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