<p>Cavitation ultrasonic surface rolling (CUSR) enhances the surface strength of 7075 aluminum alloy by inducing compressive residual stress (CRS). To reveal the mechanism of CRS evolution, this study proposed an efficient and economical analytical model that integrated the impact pressure from micro-jet generated by bubble collapse. This model predicted the CRS distribution under the coupled action of static, ultrasonic impact, and cavitation loads. It was confirmed by finite element model (FEM) and experiments. Results indicated that surface and maximum CRS values increased with the applied static load. These values exhibited a tendency to increase followed by a decline along the depth direction. CUSR generated 3.1 and 6.6 pct higher surface and maximum CRS compared to conventional ultrasonic surface rolling, respectively. This result highlights the synergistic strengthening effect of cavitation micro-jet. The analytical model achieved prediction errors within 22.92 pct relative to experiments while reducing computational cost compared to FEM. Thus, it provides a cost-effective tool for rapid acquisition of surface and maximum CRS in CUSR for aerospace and other demanding applications.</p> Graphical Abstract <p></p>

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Modeling Residual Stress in Cavitation Ultrasonic Surface Rolling of 7075 Aluminum Alloy: Mechanisms and Effects

  • Hongbo Li,
  • Jianxin Zheng,
  • Liuyin Jia,
  • Junhua Li

摘要

Cavitation ultrasonic surface rolling (CUSR) enhances the surface strength of 7075 aluminum alloy by inducing compressive residual stress (CRS). To reveal the mechanism of CRS evolution, this study proposed an efficient and economical analytical model that integrated the impact pressure from micro-jet generated by bubble collapse. This model predicted the CRS distribution under the coupled action of static, ultrasonic impact, and cavitation loads. It was confirmed by finite element model (FEM) and experiments. Results indicated that surface and maximum CRS values increased with the applied static load. These values exhibited a tendency to increase followed by a decline along the depth direction. CUSR generated 3.1 and 6.6 pct higher surface and maximum CRS compared to conventional ultrasonic surface rolling, respectively. This result highlights the synergistic strengthening effect of cavitation micro-jet. The analytical model achieved prediction errors within 22.92 pct relative to experiments while reducing computational cost compared to FEM. Thus, it provides a cost-effective tool for rapid acquisition of surface and maximum CRS in CUSR for aerospace and other demanding applications.

Graphical Abstract