Effect of Ultrasonic Rolling on Surface Integrity and Fatigue Properties of 2024-T3 Aluminum Alloy

LIANG Hao; LIU Pengtao; BAI Xuepiao; LIU Wenbo; ZHAO Xiujuan

doi:10.16490/j.cnki.issn.1001-3660.2025.13.016

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Surface Technology ›› 2025, Vol. 54 ›› Issue (13) : 184-192. DOI: 10.16490/j.cnki.issn.1001-3660.2025.13.016

Surface Strengthening Technology

Effect of Ultrasonic Rolling on Surface Integrity and Fatigue Properties of 2024-T3 Aluminum Alloy

LIANG Hao¹, LIU Pengtao^1*, BAI Xuepiao², LIU Wenbo¹, ZHAO Xiujuan¹

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Abstract

Aviation manufacturing industry is a unique branch of the manufacturing industry. Its technical level and production capacity can represent the highest manufacturing level and technical strength of a country. It plays a vital role in the modernization of national economy and national defense. 2024 aluminum alloy is widely used in structural components of aircraft due to its low density and high strength. If fatigue failure occurs, it will seriously affect the flight safety of aircraft. As a new type of surface strengthening technology, ultrasonic rolling technology has gradually attracted people's attention because of its advantages of high processing efficiency and good surface quality. In this paper, the variation of surface integrity of 2024-T3 aluminum alloy under different ultrasonic rolling parameters is studied, and the influence of ultrasonic rolling treatment on its fatigue property is studied, to provide a basis for improving the surface integrity and fatigue strength of aviation aluminum alloy components. Firstly, the aluminum alloy samples are strengthened by ultrasonic rolling equipment. The treated aluminum alloy samples are observed and measured by LEICA DCM3D microscope, SUPRA55 field emission scanning electron microscope and i-XRD X-ray stress tester. The surface roughness, surface microstructure, surface hardness, hardened layer depth and residual stress of aluminum alloy samples before and after ultrasonic rolling treatment under different process parameters are analyzed, and a rotary bending fatigue property test is carried out. The influence of ultrasonic rolling treatment on the fatigue life of the samples is compared and analyzed, and the strengthening and modification mechanism of aluminum alloy ultrasonic rolling treatment is studied. The results show that the surface roughness of the samples after ultrasonic rolling is much lower than that of the original samples, and the lowest roughness reaches 0.197 μm, with a decrease of 85.6%. The surface hardness of the sample after ultrasonic rolling treatment is up to 192.47HV, which is 57.6% higher than that of the original sample. After ultrasonic rolling, the surface metal of the sample has obvious plastic rheology and grain refinement. The average grain size of the original sample without ultrasonic rolling is 36.68 μm, while the average grain size of the strict surface layer after ultrasonic rolling is 10.28 μm. After ultrasonic rolling, the fatigue strength of aluminum alloy samples increased from 130 MPa to 180 MPa, with an increase of 38.5%. At the same stress level, the fatigue life of the ultrasonic rolling treated sample is 7 times higher than that of the original sample. It can be seen from the fracture analysis of the sample that the crack source of the original sample is located on the surface of the sample, while the fatigue source of the sample after ultrasonic rolling is originated from the subsurface. After ultrasonic rolling treatment, the roughness of the sample is greatly reduced, and the surface hardness, hardened layer depth and residual compressive stress of the sample are greatly increased. The combined effect of these aspects greatly improves the fatigue strength of the aluminum alloy sample after ultrasonic rolling.

Key words

2024-T3 aluminum alloy / ultrasonic rolling process / roughness / hardness / microstructure / fatigue strength

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LIANG Hao, LIU Pengtao, BAI Xuepiao, LIU Wenbo, ZHAO Xiujuan. Effect of Ultrasonic Rolling on Surface Integrity and Fatigue Properties of 2024-T3 Aluminum Alloy[J]. Surface Technology. 2025, 54(13): 184-192 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.13.016

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