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Surface Treatment of AISI 304 Using Pulsating

Water Jet Peening

Chapter · November 2018

DOI: 10.1007/978-981-10-5329-0_40

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Surface Treatment of AISI 304 Using
Pulsating Water Jet Peening

Madhulika Srivastava, Rupam Tripathi, Sergej Hloch, Ayush Rajput,

Drupad Khublani, Somnath Chattopadhyaya, Amit Rai Dixit,
Josef Foldyna, Pavel Adamčík, Jiri Klich, Michal Zelenak
and Dagmar Klichová

Abstract Water jet peening has gained attention as a potential surface treatment
process for improving the fatigue life of a component. The tensile residual stress in
the component initiates the stress corrosion cracking and reduces its fatigue life.
The mitigation of this tensile residual stress can be effectively achieved by water jet
peening process due to its resistance to corrosion, flexibility in treating complex
areas and capability to maintain the eco-friendly environment. In the present work,
the AISI 304 plates were treated with pulsating water jet (actuator frequency
f = 20.19 Hz) at the pressure of p = 20 MPa with traverse speed of v = 0.5 mm/s
and v = 2.5 mm/s using two different types of nozzles; flat nozzle of diameter

M. Srivastava (&)
R. Tripathi
A. Rajput
D. Khublani
S. Chattopadhyaya
A.R. Dixit

Department of Mechanical Engineering, Indian Institute of Technology
(Indian School of Mines), Dhanbad 826004, Jharkhand, India
e-mail: madhulikamech3003@gmail.com
R. Tripathi
e-mail: rupam.tripathi10@gmail.com
A. Rajput
e-mail: ayushrajput49@gmail.com
D. Khublani
e-mail: khublani@gmail.com
S. Chattopadhyaya
e-mail: somuismu@gmail.com
A.R. Dixit
e-mail: ar.dixit@mece.ism.ac.in
S. Hloch
Faculty of Manufacturing Technologies, TU of Košice with the seat in Prešov, Bayerova 1,
Presov 080 01, Slovak Republic
e-mail: hloch.sergej@gmail.com
S. Hloch
J. Foldyna
J. Klich
M. Zelenak
D. Klichová
Department of Material Disintegration, Institute of Geonics Academy of Science of Czech
Republic, Studentska, Ostrava, Poruba 708 00, Czech Republic
e-mail: josef.foldyna@ugn.cas.cz

© Springer Nature Singapore Pte Ltd. 2018 535

M.K. Singh et al. (eds.), Applications of Fluid Dynamics, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-10-5329-0_40
536 M. Srivastava et al.

d = 1 mm (HAMMELMANN) and circular nozzle of diameter d = 1.9 mm

(STONEAGE). The microstructural analysis of the treated and untreated region was
conducted to analyse the effect of traverse speed and the type of nozzle on the
erosion process. The study revealed that more erosion occurs at lower traverse
speed; however, fewer surface depressions were observed in the case of flat nozzles.
The X-ray diffraction technique was also used to analyse the effect of traverse speed
and the type of nozzle on the residual stress of the samples. In addition to this, the
acoustic emission during the ongoing process was monitored using LabView 2012
SP1 f5 ver. 12.0.1. The results indicate that acoustically monitored pulsating water
jet peening process can be used as tool for the controlled local treatment process
arising from the impact of the pulsed water jet on the surface of sample.

Abbreviations and Symbols

WJP Water jet peening
PWJ Pulsating water jet
XRD X-ray diffraction
FESEM Field emission scanning electron microscope
AE Acoustic emission
f Frequency (kHz)
d Diameter of the nozzle (mm)
v Traverse speed (mm/s)
p Pressure (MPa)
z Stand-off distance (mm)

1 Introduction

Austenitic stainless steel (AISI 304) has wide mechanical, automotive and nuclear
applications as it inherits magnificent properties such as high toughness, better
corrosion resistance, high ductility, drawability and formability. These components
possess residual stress, which has the tendency to improve or deteriorate the

J. Klich
e-mail: jiri.klich@ugn.cas.cz
M. Zelenak
e-mail: michal.zelenak@ugn.cas.cz
D. Klichová
e-mail: dagmar.klichova@ugn.cas.cz
P. Adamčík
Technická Diagnostika, Ltd., Jilemnického 4, Prešov 080 01, Slovak Republic
e-mail: tdg@diagnostika.sk
Surface Treatment of AISI 304 Using Pulsating Water Jet Peening 537

component depending on their magnitude and nature. The positive effect of com-
pressive residual stress is widely used in industries. Over the years, possible
methods are being adopted to improve the adverse effect of the residual stresses
such as shot peening, laser shock peening and water jet peening (Meguid et al.
1999). Water jet peening has emerged as a promising technique for mitigating the
stress corrosion cracking which results into the improvement of the residual stresses
and the fatigue life of the component (Srivastava et al. 2016). The possible
drawbacks associated with shot peening, i.e. defects and rough surface, which has
pernicious effects to fatigue crack initiation have been eliminated in the water jet
peening process (Eftekhari et al. 1995). In addition to this, WJP method does not
involve any thermal effects as in laser peening (Ding and Ye 2006). In the WJP
process, the droplets of water are impinged against the surface being treated. The
impact of the droplets generates a surface pressure distribution that exceeds
the yield strength of the material. A localized plastic deformation is induced by the
peak loads that are constrained by the surrounding material thereby inducing high
compressive residual stress (Hashimoto et al. 2013) (Fig. 1).
Water jet technology in recent times is being used in varieties of applications
such as cleaning, cutting, paint removal, surface textures and increasing fatigue life
of the component by imposing positive effects compressive residual stress in the
subsurface layer (Mochizuki et al. 1993). Water jet as a tool for surface treatment
refers to any process that is used to modify, enhance or remove the exposed
surfaces of a component or structure. The applications that require surface treatment
range from low-precision process like rust removal from ship hulls to control
processes such as texture automotive cylinder bores to promote the adhesion of
thermal spray coatings. A continuous water jet has several modifications like AWJ
and PWJ (Foldyna et al. 2004, 2009, 2012). WJ and AWJ are presently being used
in industries and have some economic and technological limitations. The current

Fig. 1 Mechanism of water jet peening

538 M. Srivastava et al.

industry is trending towards erosion of materials at lower pressures for different

applications. This could be achieved by using pulsating water jet (Lehocka et al.
2016; Zelenak et al. 2015). Pulsating water jet involves initially a continuous jet
exiting from the nozzle which later turns into individual clusters of fluid.
Eventually, the material is then treated with high-energy droplets. Over the years,
attempts are being made to attain the discontinuity of the jet, but the modification of
continuous jet in form of pulses is found to be most advantageous (Lehocka et al.
2016). The pulsating water jet is practically being investigated for disintegration of
rocks (Vijay and Foldyna 1994; Tripathi et al. 2016), redevelopment of concrete
structures (Foldyna 2011), scale removal from steels (Hnizdil and Raudensky
2010), erosion of metals (Foldyna et al. 2012) and in medicine for dental hygiene
(Sharma et al. 2008), orthopaedics and traumatology (Hloch et al. 2013a, b) and
dermal medicine (Akbari and Shafii 2002). In this study, an attempt has been made
to utilize the effectiveness of PWJ for the surface treatment process.
In the past decades, possible attempts had been made to analyse the effect of
various process parameters such as jet pressure p (MPa) and traverse speed
v (mm/min) on the residual stress, the roughness and the erosion of the component.
Colosimo et al. (2000) explained the empirical relation between the peening
parameters, residual stress and surface roughness of the material. Ramulu et al.
(2000) evaluated the effect of high-pressure water jet on the surface integrity and
texture of the metal through an experimental study. The residual stress fields
obtained after the treatment were analysed to distinguish the influence of material
properties. Arola et al. (2001) observed that the residual stress on the surface of
titanium alloy after water jet peening increased with increasing pressure, and also
negligible change in roughness was observed. The experimental study of water jet
peening at 600 MPa (Hashish et al. 2005) revealed that plastic deformation was
achieved at much deeper layers in case of water jet peening than laser peening. The
degree of the deformation was found to be dependent on the peening parameters
and the desired surface roughness. Also, a comparative study between water jet
peening and shot peening on aluminium alloy depicted that the compressive stress
induced near the strengthened surface by water jet peening was higher than shot
peening, thereby more increase in the fatigue life was observed in case of
water-jet-peened surface. Though many works had been reported regarding the
effect of residual stress on the surface treated by water jet, efforts are required to
cover the large range of materials and to analyse the variation of the changing
process parameters.
Online monitoring of acoustic emission in the recent years has been used
effectively for defect analysis during the ongoing process (Hloch et al. 2013a, b).
Valicek and Hloch (2010) utilized the negative characteristic of noise as a source of
information to describe the ongoing process. The appropriate application of sensors
monitors the AE generated during the process for the fault detection. For instance,
in the case of abrasive water jet cutting insufficient cutting depth, choked orifice,
etc. was detected by using acoustic emission as an indirect monitoring tool (Hassan
et al. 2004). Hreha et al. (2012) attempted to monitor the vibrations generated
during the hydro-abrasive cutting of stainless steel and observed that fault
Surface Treatment of AISI 304 Using Pulsating Water Jet Peening 539

conditions like broken focussing tube, fractured water nozzle can be detected and
controlled during the online monitoring of acoustic emission. Similarly, Hreha et al.
(2015) during the online monitoring of AWJ cutting of AISI 309 analysed the
dependency of the surface topography of the material being cut on the emission
spectrum arising during the process. The online monitoring of AE involves mea-
surement and evaluation of the ongoing phenomenon which helps in the charac-
terization of the processes accurately. It involves the collection and evaluation of
the AE (Tripathi et al. 2016). The data evaluated from the acoustic emission spectra
helps to predict the ongoing process and determine the state of PWJ during the time
of its exposure to the material. This information can be applied to any position
during the ongoing experiment on the surface of the material. The solution is highly
influenced by the input parameters of the technological process in order to achieve
the optimal parameters for preventing the disintegration of the material (Chen 2008;
Natarajan et al. 2011; Chen et al. 2011; Salak et al. 2006; Sharma 2011).
In this work, the surface of AISI 304 is treated using pulsating water jet using
two different types of nozzles; flat nozzle and circular nozzle. The microstructural
analysis was conducted to evaluate the effect of plastic deformation on the treated
surface. In order to analyse the effect of type of nozzle on the residual stress
improvement, the surface residual stresses will be measured using X-ray diffraction
method. Also, during the treatment of AISI 304 samples, indirect monitoring of
acoustic emission using LabView 2012 SP1 f5 ver. 12.0.1 was performed. The aim
of using the acoustic emission as an indirect monitoring tool is to use it as a source
of information during the ongoing process for a better control over the treatment
process.

2 Material and Experimentation

The water jet peening was performed on the surface of AISI 304 plate having
mechanical properties and composition given in Tables 1 and 2, respectively.
The AISI 304 plate (350 mm  50 mm  5 mm) was clamped on the fixture
which was attached to the frame of the machine (Fig. 3). The technological set-up
(Fig. 2) includes—plunger pump HAMMELMANN HDP 253 (maximum operat-
ing pressure—150 MPa, maximum flow rate 67 l min−1) and robot ABB IRB
6640-180 for handling the pulsating water head. The acoustic waves are generated
by ultrasonic generator Ecoson WO-UG_630-20 specially designed for pulsating
water jetting. The treatment process was performed in a linear direction along the
width of the sample using two types of nozzles: flat (HAMMELMANN) (Fig. 2a)
and circular (STONEAGE) (Fig. 2b) with the experimental conditions stated in
Table 3. Sufficient gap was maintained between the consecutive treatments in order
to avoid the overlap of the treated surface (Fig. 4). As the flat nozzle exit is
540 M. Srivastava et al.

Table 1 Composition of AISI 304

Element C (%) Mn (%) S (%) Si (%) P (%) Ni (%) Cr (%)
SS (AISI 304) 0.08 2.00 0.03 1.0 0.04 8–10.5 18–20

Table 2 Mechanical properties of AISI 304

STN W. Nr. Grade Tensile strength Yield Elongation HR Structure
Rm (N-mm−2) strength (%) Bmax.
Rp0,2 Rp1
17.240 1.4301 304 500/900 175 210 45 88 Austenitic

Fig. 2 Principle of technological set-up: a flat nozzle, b circular nozzle

elliptical in shape, it forms a wider jet at a spray angle of 10° and resulted in
rectangular cross section on the surface of the workpiece after the treatment process.
In contrast to this, the circular nozzle exit is circular in shape and resulted in circular
cross section on the surface of the workpiece.
The acoustic emission generated during the peening process was measured using
Spectral Measurements Toolkit 2.6.3 with accelerometer WR712F-M4 capable of
measuring up to 65 kHz. The AE parameters were obtained by processing the raw
AE signal using Advanced Signal Processing Toolkit 12.0.0 by LabView 2012 SP1
f5 ver. 12.0.1 (National Instrument). A piezoelectric accelerometer was fixed at the
back side of the workpiece before clamping. The two other accelerometer sensors
were also fixed for sensing the pressure in the chamber at the time of impact.
Surface Treatment of AISI 304 Using Pulsating Water Jet Peening 541

Fig. 3 Experimental set-up

Table 3 Experimental conditions

S. No. Type of nozzle d (mm) f (kHz) Z (mm) p (MPa) v (mm/s)
1. Flat 1 20 30 20 0.5
2.5
2. Circular 1.9 20 30 20 0.5
2.5

Fig. 4 Treated AISI 304

samples by pulsating water jet
using flat nozzle d = 1 mm
10° and round nozzle
d = 1.9 mm

3 Results and Discussion

3.1 AE Analysis

The acoustic emission was recorded during the peening process caused by the
impact of the pulsed water jet with the surface of the sample. These signals were
542 M. Srivastava et al.

Fig. 5 Position on the sample for AE analysis

Fig. 6 Acoustic emission signal behaviour: (a) flat nozzle, v = 0.5 mm/s; (b) flat nozzle,
v = 2.5 mm/s; (c) circular nozzle, v = 0.5 mm/s; (d) circular nozzle, v = 2.5 mm/s

recorded from the commencement of the peening process till the width of the
sample was covered (Fig. 5).
Figure 6a–d shows the acoustic emission signals recorded at different traverse
speed at pressure of 20 MPa using flat and circular nozzles. According to the
Surface Treatment of AISI 304 Using Pulsating Water Jet Peening 543

Fig. 6 (continued)

analysis of measured acoustic emission, it is possible to conclude that the signal

intensity measurement during peening with the circular nozzle is two times bigger
than using flat nozzle due to water dispersion under angle 10° of flat nozzle. As
shown in Fig. 6, the peak values of amplitude are achieved after few seconds of the
beginning of the peening process due to the commencement of the repeated impact
of the pulsed water jet on the surface of sample. The traverse speed has shown
influential behaviour in the waveform, i.e. the signal obtained using traverse speed
v = 0.5 mm/s has convex shape, while at higher traverse speed v = 2.5 mm/s it
showed a concave behaviour. At higher traverse speed v = 2.5 mm/s, the signal
intensity increases abruptly in the case of flat nozzle. However, the circular nozzle
showed a significant change in which the low traverse speed v = 0.5 mm/s causes
low actuation particular in the middle part of the sample and high traverse speed
v = 2.5 mm/s actuates middle part of the sample to the edge of the sample more.
The possible reason behind this variation could be the plastic deformation that
occurs more at lower traverse speed. The present results show the important dif-
ference in the shape of the signals with the variation in the traverse speed.
544 M. Srivastava et al.

Therefore, these acoustic emission results can be used as important source infor-
mation about the ongoing plastic deformation during the surface treatment process.

3.2 Surface Erosion

After the treatment of AISI 304 by pulsating water jet, the microstructural analysis
of the surface was examined using FESEM (FESEM Supra 55 having resolution of
0.8 nm at 15 kV, and 1.6 nm at 1 kV; 12-1000000X magnification; 100 V to
30 kV acceleration voltage; and Schottky field emission electron gun.). These
micrographs were taken at 500 magnification as shown in Fig. 7a–e. The
microstructure of AISI 304 surface indicates noticeable erosion in the treated region
in form of small depressions. These depressions are more visible for the treatments
subjected to lower traverse speed (Fig. 7b, c). Therefore, it can be interpreted that
the erosion mechanism is dependent upon the duration of the impact of pulsed
water jet with the target material which, in turn, is dependent upon the traverse
speed. From Fig. 7a (original surface) and Fig. 7b–e (treated surface), it can be
noted that substantial amount of erosion occurs on the surface after the treatment
process. For the same parameter, the treatments carried out with flat nozzle
(Fig. 7b, d) showed fewer surface depressions or less severe erosions as compared
to treatments carried out using circular nozzle (Fig. 7c, e). In Fig. 7c, it was
observed that disintegration of material occurs in case of circular nozzles when
treated at traverse speed of 0.5 mm/s; however, under same parameter, the
micrograph of flat nozzle showed the occurrence of surface depressions Fig. 7b.
Figure 7f was observed at 1000 magnification which shows the main impact
zone and cavities created after the treatment process. These cavities are the result of
peening mechanism in which the droplets impact the surface being treated and lead
to plastic deformation which is constraint by the surrounding material.

3.3 Residual Stress Measurement

The residual stress measurements are conducted using X-ray diffraction method by
Panalytical High Resolution XRD-I, PW 3040/60 (Fig. 8). The measurements will
be conducted on the surface of samples treated with round and flat nozzles as shown
in Fig. 9.
The residual stresses will be measured on the surface of the untreated and treated
regions to evaluate the changes before and after the treatment process and also to
evaluate the influence of geometry of nozzle on the residual stress improvement.
Due to certain limitations, these tests could not be conducted at present, but in
future the results will be evaluated and reported.
Surface Treatment of AISI 304 Using Pulsating Water Jet Peening 545

(a) Untreated surface (b) Flat nozzle (v=0.5m/s, P=20MPa)

(c) Circula rnozzle ( v=0.5m/s, P=20MPa) (d) Flat nozzle (v=2.5m/s, P=20MPa)

(e) Circular nozzle ( v=2.5m/s, P=20MPa) (f) Circular nozzle (v=2.5m/s, P=20MPa)

Fig. 7 FESEM images of treated and untreated AISI 304 samples

546 M. Srivastava et al.

Fig. 8 X-ray diffraction

machine

Fig. 9 Sample for residual

stress measurement

4 Conclusion and Future Scope

This experimental investigation presents a new and effective method for the surface
treatment process. The AISI 304 plates are treated using pulsating water jet using
two different types of nozzles, flat and circular, at different set of parameters. From
the present study, the following conclusions can be made:
(i) The microstructural analysis of the treated samples revealed that more ero-
sion or surface depressions were observed on the surface of the samples that
are treated at lower traverse speed.
(ii) Considering the effect of geometry of the nozzle on the surface erosion, it
was observed the flat nozzle leads to less surface erosions as compared to
circular nozzle when treated under same conditions.
(iii) The acoustic emission signals recorded during the peening process showed a
influential behaviour on the traverse speed. The waveform showed convex
behaviour for low traverse speed and concave behaviour for high traverse
speed.
Surface Treatment of AISI 304 Using Pulsating Water Jet Peening 547

(iv) The signal intensity obtained for circular nozzle was more than the flat nozzle
due to water dispersion at an angle of 10°.
(v) These acoustic emission results can be used as important source information
for performing a controlled treatment process on the surface of the specimen.
Further, in the future, the effect of treatment on the residual stress will be
evaluated to check the effectiveness of the process as a surface treatment technique.
Also, the acoustic emission recorded during the peening process is interpreted
according to the residual stress results obtained in order to present an effective way
to control the parameters hence, maintaining the surface integrity.

Acknowledgements This work was supported by the Slovak Research and Development Agency
under Contract No. APVV-207-12 and Indian Institute of Technology (Indian School of Mines),
Dhanbad, India. Experiments were carried out with the support of the Institute of Clean
Technologies for Mining and Utilization of Raw Materials for Energy Use—Sustainability
Program, reg. no. LO1406 financed by Ministry of Education, Youth and Sports of the Czech
Republic, and with support for the long-term conceptual development of the research institution
RVO: 68145535.

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