A number of wire samples with different diameters and/or coatings were subjected to UP treatment in the WireTreat™ system using different technological parameters of the UP process. Positive results were achieved in increasing the fatigue life of the treated wires.
In general, according to experimental data, the harmful tensile residual stresses on the surface of wires of small diameters (up to 0.9 mm) may reach levels from 200 MPa to 500 MPa.
The results of residual stress evaluation as well as fatigue testing of wires with different diameters confirmed that UP treatment of the wires caused a significant relaxation of harmful tensile residual stresses and fatigue life improvement.
A number of enabling R&D projects were completed to evaluate the efficiency of application of Ultrasonic Peening (UP) technology for treatment of wires to improve the quality of surface and material texture, beneficial redistribution of residual stresses, fatigue life improvement and production of thin tapes from wires. Such tape has improved mechanical properties and could be applied in tire production. A certain range of wire diameter was considered starting from 0.15 mm.
Based on the preliminary experimental results, the Ultrasonic Peening is considered asa promising technique for beneficial redistribution of residual stresses in wires and fatigue improvement. The main critical point in UP treatment of wires is thedevelopment of the optimum technology: minimum cost-time-labor with maximum speed and beneficial effect. The UP process could be applied on line in combination with high-speed wire drawing.
Y. Kudryavtsev, J. Kleiman, G. Prokopenko, B. Mordyuk, T. Krasovskiy P. Mikheev and V. Knysh. Computerized Complex for Ultrasonic Peening of Parts and Welded Elements. 32-nd Annual Ultrasonic Industry Association Symposium. New York, NY, USA, October 21-23, 2002. (on CD)
Y. Kudryavtsev, J. Kleiman, G. Prokopenko, P. Mikheev and V. Knysh. Mechanism and Efficiency of Ultrasonic Peening in Fatigue Improvement. SEM Annual Conference & Exposition on Experimental and Applied Mechanics. Milwaukee, Wisconsin, USA, June 10-12, 2002. (on CD)
Y. Kudryavtsev, J. Kleiman, G. Prokopenko et al. Optimum Application of Ultrasonic Peening. SEM Annual Conference and Exposition: Experimental Mechanics in Emerging Technologies. Portland. Oregon. USA, June 4-6, 2001. p. 179-182.
Y. Kudryavtsev, J. Kleiman, G. Prokopenko et al. Ultrasonic Peening of Weldments: Experimental Studies and Computation. IX International Congress on Experimental Mechanics. Orlando. Florida. USA, June 5-8, 2000. p. 504-507