FerroECOBlast provides excellence in the most demanding challenges of surface treatment.
Add more value to your high-tech products and increase their lifetime, while protecting them against failures such as fatigue, fretting fatigue and stress corrosion cracking with our technology of shot peening.
Our proven shot peening technology guarantees increased fatigue strength up to 800% and the fatigue life up to 1000%.
Shot peening is a cold working process in which the surface of a part is bombarded with small spherical media called shot. Each piece of shot striking the metal acts as a tiny peening hammer imparting a small indentation or dimple on the surface. In order for the dimple to be created, the surface layer of the metal must yield in tension.
Below the surface, the compressed grains try to restore the surface to its original shape producing a hemisphere of cold-worked metal highly stressed in compression. Overlapping dimples develop a uniform layer of residual compressive stress.
It is well known that cracks will not initiate nor propagate in a compressively stressed zone. Because nearly all fatigue and stress corrosion failures originate at or near the surface of a part, compressive stresses induced by shot peening provide significant increases in part life. The magnitude of residual compressive stress produced by shot peening is at least as great as half the tensile strength of the material being peened.
In most modes of long term failure the common denominator is tensile stress. These stresses can result from externally applied loads or be residual stresses from manufacturing processes such as welding, grinding or machining. Tensile stresses attempt to stretch or pull the surface apart and may eventually lead to crack initiation. Because crack growth is slowed significantly in a compressive layer, increasing the depth of this layer increases crack resistance.
On the beginning of 20th century shot peening established itself as a full scale production process. The modern transport and jet era of the mid-20th century demanded more reliable, safe and well-engineered mechanical drives and structures. This was when modern shot peening was established and supplemented with a clever measuring method invented by John Almen. Shot peening went from “hitting more” to “hitting smarter”.
From this point onwards, it was all about speed, efficiency, control, accuracy and repeatability. Technological achievements in the fields of process control and electro-mechanical drives led this process from rigid one-axis automation to the point of smart CNC and robotic driven systems and shot peening earned its label of being sophisticated.
Where is our shot peening solution applicable?
This is where our company Ferrocrtalic comes into the picture with its range of complete shot peening solutions. After a few decades of coping in the restricted market of the former communist country of Yugoslavia, the company learned how to master delivering a shot. It was the fine art of propelling a small particle towards the object of interest with the goal of achieving the required result and the peening effect was one of them. When Slovenia opened up towards the western markets, all these smart new process technologies, as shot peening, formerly available only to the “limited club” became achievable for us.
As an addition to machine building for our most demanding customers we also provide peening services for trial purposes or full scale production peening of their products.
Today, the utilisation of different technologies, and know-how of shot peening process, enabled us to solve even the most difficult shot peening tasks. For some of our customers, a simple turntable design with a linear driven nozzle or linear through-feed system is more than enough, but for others only the sky is the limit. These days in our company, we are dealing with the integration of eight or more axis manipulation systems, dual robotic manipulation, digital closed loop process controls exceeding the limits of the available standard of shot peening systems. Our machine controllers are performing real time data acquisition and on-screen display of the vast numbers of machine parameters considering all the “classics” defined by the AMS specification and also some unorthodox ones. All with the goal of delivering the ultimate solution for our clients.
When dealing with customer specifications and requirements, our technical teams are constantly challenged, but never frightened. Ferroecoblast’s experienced engineering team is well equipped for the task, considering the large robotic cell with enough space to fit a complete landing gear assembly and enough flexibility to deal with most challenging work piece geometries. Not to forget our clever laboratory capable of looking into the surface crystal structure.
Usually there is a solution to the problem and most often it’s a simple one. But one must ask where the limit is? When is enough? When do the expectations of modern material and process engineers switch from being smart to being almost non-realistic and obsessed? At the end we evaluate the performance of the shot peening process using the well-established old-fashioned yet never outdated Almen test and visual methods for determining coverage.
Shot peening is the most economical and practical method of ensuring surface residual compressive stresses.
More about shot peening equipment.
Shot peen forming is extremely flexible cold forming process derived from shot peening and enables forming of complex shapes, which using conventional methods would require a lot of machining resources and power consumption. Peen forming is used to form the most complex curvatures of aluminium wing skins in manufacturing of airplanes. Peen forming is also used to form airplane fuselage shells, and tank segments for expendable launch systems for space industry.
Peen forming is often more effective in shaping curvatures rather than rolling, pressing or bending. Also saddle forms can be achieved with peen forming. Since peen forming is performed without the use of dies, material consumption due to circumcision is greatly reduced, and eliminates the high cost of development and manufacturing of dies.
Peen forming is so flexible it can further modify the shape once it has been made.
More about shot peen forming technology.