Optics & Laser Technology 77 (2016) 169–176

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Optics & Laser Technology

journal homepage: www.elsevier.com/locate/optlastec

Effect of laser peening with different energies on fatigue fracture

evolution of 6061-T6 aluminum alloy$
J. Sheng, S. Huang n, J.Z. Zhou, J.Z. Lu, S.Q. Xu, H.F. Zhang
School of Mechanical Engineering, Jiangsu University, Zhenjiang 212013, PR China

art ic l e i nf o a b s t r a c t

Article history: To deeply understand the effect of laser peening (LP) with different laser pulse energies on 6061-T6
Received 25 June 2015 aluminum alloy, the fatigue fracture morphologies evolution process at various fatigue crack growth
Received in revised form (FCG) stages and the corresponding strengthen mechanism were investigated. At the initial stage of FCG,
16 August 2015
more fatigue micro-cliffs were found after LP, while the fatigue striation spacing simultaneously reduced.
Accepted 7 September 2015
A “stop-continue” phenomenon of crack propagation was discovered for laser peened samples. The fa-
tigue striation spacing at the middle stage of FCG increased significantly while compared with that at the
Keywords: initial stage, in addition, the fatigue striation spacing decreased with an increase in laser pulse energy.
6061-T6 aluminum alloy Fracture morphologies in transition region of laser peened samples exhibit a mixing fracture char-
Laser peening
acteristic of striations and dimples. The laser peened sample with laser pulse energy of 7 J presents more
Fatigue fracture evolution
circuitous growing paths. Due to the complex stress state induced by LP, dimples with different sizes
Morphology
appeared in the final fracture region.
& 2015 Elsevier Ltd. All rights reserved.

1. Introduction peened specimens were improved [17–18]. Attributed to its con-

6061-T6 aluminum alloy is an Al–Mg–Si–Cu alloy with ex-
cellent performances of corrosion resistance, weldability, im-
munity to stress-corrosion cracking and deformability [1]. Its low
density gives an additional advantage of lightweight, makes 6061-
T6 aluminum alloy widely used in aerospace industry. Generally,
aeronautical parts like aero-engine blades always work in severe
conditions, for instance, high temperature and humidity, cycle
loading, strong vibration, etc. The severe working environment
accelerates the failure of 6061-T6 parts due to micro-cracks, stress-
corrosion, etc.
To prolong the service life of aeronautical parts, advanced
surface modification technologies have been developed, such as
shot peening [2–3], deep-rolling [4], low-plasticity burnishing [5],
roller-burnishing [6] and laser peening (LP) [7–11]. Among the
above surface modification technologies, LP is a competitive pro-
cess which can significantly improve the fatigue properties by
inducing higher amplitude and greater depth of compressive re-
sidual stress [12–14]. Furthermore, micro-structures evolution
induced by LP, like grain refinement and dislocation density in-
crease, were observed in previous researches [15–16]. The asso-
ciated mechanical properties and fatigue performances of laser
☆
Invited paper for the section: Hot topics in Metamaterials and Structures.
n
Correspondence to: Xuefu Road 301, Jinkou District, Zhenjiang 212013,
PR China.
E-mail address: huangshu11@sina.com (S. Huang).
tributions in prolonging fatigue lifetimes, LP has been intensively
investigated onto 6061-T6 titanium alloy. Sathyajith et al. [19]
utilized LP to intensify 6061-T6 alloy with low energy of 300 mJ
under two pulse densities, 22 pulse/mm2 and 32 pulse/mm2. An
increment of 190% on surface compress stress was found after LP
treatment. The peening effect pertain up to a depth of 1.2 mm
from the surface was revealed. Furthermore, Ren et al. [20] in-
vestigated the influence of LP process on residual stress relaxation
of 6061-T651 aluminum alloy at elevated temperatures. The re-
sults showed that LP still has a beneficial effect on residual stress
at 300 °C. The metallographic structure evolution at a further
elevated temperature was also studied in Ren's research. More-
over, micro-hardness and tensile properties of 6061-T6 aluminum
alloy after single and double shot of LP under water was discussed.
The hardness showed an increment of 26% for the double shot of
LP treatment [21]. It seemed that a better tensile strength was
obtained by the combined effects of induced compressive residual
stress and high density dislocation arrangement during the LP
process. The uniform elongation was improved from 3.2% to over
5.8% by LP. To sum up, the strengthening effect produced by LP on
mechanical properties of 6061-T6 aluminum alloy has been widely
recognized. As research continues, more attentions have been paid
to the fatigue performance of 6061-T6 aluminum alloy subjected
to LP treatment [22–23]. Fatigue crack growth (FCG) and fracture
toughness were preliminarily discussed.
In fact, the characteristic of fracture microstructure can directly
reflect both macroscopic and microscopic performances of

http://dx.doi.org/10.1016/j.optlastec.2015.09.008
0030-3992/& 2015 Elsevier Ltd. All rights reserved.
170 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176
metallic materials when studying fatigue properties. Thus, it is
crucial to understand the fatigue crack initiation (FCI) and FCG
mechanism of laser peened specimens based on fracture
morphologies. Therefore, our team had examined the effect of LP
treatment on mechanical properties and fatigue fracture
morphologies of 6061-T6 aluminum alloy [16], furthermore, the
improvement mechanism of FCG resistance of 6061-T6 aluminum
alloy subjected to LP with different coverage areas and impacts
was revealed [24]. Our research well described the detailed evo-
lution process of fatigue crack from initiation to final fracture.
However, there is still dearth of data to establish a systematic
fracture analysis mechanism for 6061-T6 aluminum alloy sub-
jected to LP treatment. We have found that the macroscopic and
microscopic characteristics at the stages of initiation, middle and
final fracture of FCG are completely different in our previous ex-
periments but lack of further investigating [25].
Hence, the objective of this paper is to study the influence of LP
with different laser pulse energies on the fatigue crack propaga-
tion behavior of 6061-T6 aluminum alloy. The fatigue fracture
characteristics of laser peened samples at different FCG stages are
deeply examined. The strengthening mechanism of LP process on
6061-T6 aluminum alloy is also elucidated by the fracture micro-
structure observation.
2. Experimental procedures
2.1. Experiment samples
Plates of 6061-T6 aluminum alloy with a thickness of 6 mm
were machined to compact tension (CT) samples as illustrated in
Fig.1. The chemical composition (wt%) of 6061-T6 aluminum alloy
was: 0.90Mg, 0.62Si, 0.33Fe, 0.28Cu, 0.17Cr, 0.06Mn, 0.02Ti, 0.02Zn.
The mechanical properties were shown as follows: yield strength
sy was 289.9 MPa, tensile strength sb was 328 MPa, elastic mod-
ulus E was 69.8 GPa and Possion's ratio v was 0.33. A fatigue pre-
crack with a length of 2.5 mm (from notch tip) was made on each
sample by a MTS-809 servo-hydraulic system at ambient tem-
perature (25 °C) in the air. The maximum external load was 3.0 kN.
The load ratio was maintained at R¼ 0.1 and the frequency was
9 Hz with tensile sinusoidal form. A total length of 15 mm for the
Fig. 1. Dimension of 6061-T6 CT samples used in the FCG test.
initial crack was obtained. The samples were polished with SiC
paper with different grades of roughness followed by ethanol ul-
trasonic cleaning.
2.2. Laser peening processing
A Q-switched Nd: YAG laser system was used to produce high
energy shock wave, operating at 5 Hz repetition-rate with a wa-
velength of 1064 nm, and the laser pulse energies were 3 J, 5 J, 7 J.
The footprint of laser spot with a diameter of 3 mm was top-hat
and the FWHM of the pulses was 10 ns. Two side LP was adopted
while the swept area and direction were shown in Fig. 1. The
overlapping rate between the adjacent spots along both the par-
allel direction and perpendicular direction was 50%. A water cur-
tain with a thickness of 1–2 mm was used as the transparent
confining layer and the professional Al foil with a thickness of
100 μm was used as an absorbing layer to protect the surface of
samples from thermal ablation.
2.3. Fatigue crack growth test
FCG test was performed at ambient temperature in the air. CT
samples were fixed by chucks on a MTS-809 servo-hydraulic sys-
tem, as shown in Fig. 2. To avoid strong vibration, a maximum
external load of 3.0 kN was maintained and the load ratio R was
set as 0.5. A frequency of 5 Hz with a tensile sinusoidal form was
used. COD silicon chucks were adopted to monitor the whole FCG
process. Samples 1–3 were untreated with LP, samples 4–6, 7–9
and 10–12 were laser peened with the laser pulse energies of 3 J,
5 J and 7 J, respectively. The sample which has typical fatigue
fracture characteristics among the three samples in each group
were taken to analyze.
2.4. Fatigue fracture surface observation
The fatigue fracture microstructures of the samples with and
without LP treatment at the different FCG stages were examined
by a JSM-6700F JEOL scanning electron microscopy (SEM). The
resolution ratio of the SEM was 1.0 nm(15 kv)/2.2 nm(1 kv) while
EDS element analysis ranged from B5-U92.
 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176 171

Fig. 2. MTS-809 FCG test system and the fixture of 6061-T6 CT sample.

3. Results and discussions
After fatigue tests, final fatigue lives of the typical fracture
specimens were obtained. The corresponding fatigue lives of un-
treated and laser peened specimens with 3 J, 5 J, 7 J were 80 477,
102 687, 115 963, 137 422, respectively. Note that a maximum in-
crement of 70.8% of fatigue life was achieved after LP with the
energy of 7 J. It is obvious that LP effectively enhanced the fatigue
lives of treated specimens. In particular, the fatigue life cycle was
positively correlated with the laser power in a certain range,
which is consistent with the result in Liu's study [26].
It is well known that LP can induce high amplitude compres-
sive residual stress both on the treated surface and sub-sur-
face [11]. Rubio-González [22] revealed that the higher pulse
density induced larger compressive residual stress both perpen-
dicular and parallel to the pulse swept direction. As a result, the
induced compressive residual stress compelled the crack to close
and reduced the effective driving force, which is favorable for the
reduction of stress intensity factor range ΔK and FCG rate da/dN.
On the other hand, laser energy largely affected the FCG rate,
furthermore, the decrement of da/dN exhibited higher value
induced by lager laser energy. It was attributed to the introduction
of higher compressive residual stress distribution perpendicular to
the crack growth direction [25].
In our previous investigation [25], an effective stress intensity
factor range ΔK2-eff was proposed, which inferred that LP-induced
compressive residual stress can counteract the tensile stress, and
decreases crack driving force as well, finally retards the fatigue
crack growing [25]. To deeply understand the fracture mechanism,
fatigue fracture observations were carried out.
3.1. Macroscopic fatigue fracture morphologies
To observe the macroscopic fatigue morphologies, the fractures
were firstly washed in a KQ3200E ultrasonic cleaning machine
which was filled with ethanol, and then dried manually. Fig. 3
shows the macroscopic and localized magnification views of fati-
gue fractures on 6061-T6 CT samples subjected to different laser
pulse energies. As can be seen from Fig. 3, the typical macroscopic
fatigue fracture consists of the wire cutting notch, pre-crack, FCG,
and final fracture region, sequentially distribute from left to right.
In the FCG test, the crack initiates from the pre-crack and then

Fig. 3. Macroscopic and localized magnification views of fatigue fractures on 6061-T6 CT samples subjected to different laser pulse energies: (a) untreated, (b) 3 J, (c) 5 J and
(d) 7 J.
172 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176
Fig. 4. FCG path at initial stage of FCG on CT samples subjected to different laser pulse energies: (a) untreated, (b) 3 J, (c) 5 J and (d) 7 J.
propagates. The FCG region with bright and refined crystalline
grained feature can be observed. The macroscopic crack exhibits a
nature color of matrix. In addition, the residual plastic deformation
near the FCG region is negligible, and the morphology seems flat
and straight. Apparently, the crack growth direction is perpendi-
cular to the major stress. The final fracture region without metallic
luster is separated by a curved crack-tip line from the FCG region,
as shown in the right side of Fig. 3(a).
Note that the section size of the FCG region increases after LP,
and the higher the pulse density, the larger the section size.
Moreover, from Fig. 3(b) to (d), the upper and lower surfaces in the
FCG region corresponding to the LP area, after LP treatment, sev-
eral crack arrests can be observed, which indicates that the FCG
has been significantly hindered by LP.
3.2. Microscopic fatigue fracture morphologies
3.2.1. Initial stage of FCG
Fig. 4 shows the propagation paths at the initial stage of FCG. As
can be seen from Fig. 4(a), the crack propagation occurs directly at
the pre-crack region. The crack propagation direction is perpen-
dicular to the major stress. However, due to the residual stress and
microstructures of materials such as grain boundaries, grain or-
ientation, inclusions, and second phase particles, the crack does
not always propagate along one direction. Some localized fatigue
crack propagation paths deflect and reverse. In the FCG region,
large amount of fatigue cycle striations are observed, even on tiny
fracture faces. The fatigue cycle striation is a typical microscopic
morphology of fatigue crack at the stable propagation stage. Fig. 4
(b)–(d) shows the fatigue crack propagation paths at the initial
stage after LP with energies of 3 J, 5 J and 7 J, respectively. While
compared with the untreated samples, more fatigue micro-cliffs
appear after LP. What's more, an increase in laser pulse energy
results in an increase in the micro-cliffs amount. We can infer that
the fatigue crack propagation paths after LP become more tor-
tuous, which may lead to more strain energies consuming during
crack propagation. Yonder et al. [27] found that the grain size has
significant impact on the inhibition of FCG. The smaller the grain
size, the more the grain boundaries counteract the crack propa-
gation. It has been widely recognized that LP can refine the grain
size on the surface and sub-surface, and the refinement effect
turns to be more obvious with the increase of laser energy [15]. As
a result, the refined grains after LP increase the grain boundaries
and decelerate the crack propagation rate.
Localized magnification views of fatigue striations are shown in
Fig. 5. The views of Fig. 5(a)–(d) corresponding to the regions of A,
E, I, M in Fig. 3, respectively. It is clearly observed in Fig. 5 that the
fatigue striations parallel to each other. Furthermore, the striations
are cambered outwards and perpendicular to the direction of lo-
calized crack propagation.
An average spacing of 0.25 μm for the untreated sample are
presented in Fig. 5(a). However, after LP with laser pulse energies
of 3 J, 5 J and 7 J, the corresponding fatigue striation spacing re-
duces to 0.18 μm, 0.12 μm and 0.08 μm, respectively, as shown in
Fig. 5(b)–(d). The fatigue striation spacing is the approximation of
FCG rate [16]. This implies that initial crack propagation rate re-
duces after LP, and the rate decreases with an increase in laser
energy. The fatigue process can be regarded as a slipping process,
and any factor affecting the slipping will change the characteristics
in the fatigue fracture. Normally, the factors which inhibiting the
slipping will decrease the FCG rate and fatigue striation spacing.
We can infer that the induced high-amplitude residual stress
significantly decreases the crack-tip stress intensity factor of
samples, eventually decreases the FCG rate.
The evolution of fatigue striations is a localized process, during
which the fatigue striations could be different due to various of
microstructures like grain orientation, grain boundaries, the sec-
ond phase particles, etc. In the micro scale, the crack propagation
path depends on the microstructure characteristic that the crack
passes through.
In addition, the fatigue striations may distribute on different
planes, and can step over from one plane to another, as shown in
Fig. 6.
The grain orientation may change the normal direction of fa-
tigue striations and even the morphology. Even in the randomly
distributed grain array, the localized direction of crack propagation
depends on the relative orientation of grains in crack-tip. In the
micro scale, the major crack front is not totally straight. Crack front
tunnel may appears in some localized regions at major crack front
due to the existence of preferred orientation grains [28]. It can also
 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176 173

Fig. 5. Fatigue striation morphologies at initial stage of FCG on CT samples subjected to different laser pulse energies: (a) untreated, (b) 3 J, (c) 5 J and (d) 7 J.

been observed from Fig. 6(a) to (c) that FCG is inhibited when
encounters the grains with intensify phase. This cause the spacing
and curvature of fatigue striations change, even rupture. When
encounters the twin structure, the crack front separates and de-
viates, forming a “tongue” shape, as shown in Fig. 6(d). Conse-
quently, the cracks are unconnected and separated, result in an
enhancement in the fracture toughness.
3.2.2. Cracks with “stop-continue” phenomenon
The “stop-continue” phenomenon was observed in the fracture
as shown in Fig. 7.
It can been seen that strip extension mechanism is still domi-
nated. The clear crack frontier illustrates some irreversible changes
in the crack-tip, forming a few residual fracture surface pattern
areas. It can be clearly seen that the refined striations are parallel
to the crack propagation direction and distribute in the crack-tip
areas. These refined striations may be formed during the crack
deceleration. The crack propagation restarts at somewhere in the
crack frontier with slowly speed. SEM images present that the
crack surface angles are different before and after crack stop. This
may be caused by the redistributed stresses, which generate a
misorientation when crack growing restarts.
The position with “stop-continue” morphology on the fatigue
fracture corresponds to FCG retardation region. Further, in such
region, the extended crack stop propagating in the area with high
compressive residual stress. The crack growth rate decreases or
even stop growing.

Fig. 6. Fatigue striation pattern of adjacent grains along different planes and directions: (a) untreated, (b) 3 J, (c) 5 J and (d) 7 J.
174 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176

Fig. 7. SEM of the “stopped-continue” crack front during the fatigue test of CT samples subjected to different laser pulse energies: (a) 3 J, (b) 5 J and (c) 7 J.

3.2.3. Middle stage of FCG
Fig. 8 shows the magnification views of B, F, J, N in Fig. 3. The
crack propagation path and microstructure were revealed when
the crack length reaches 25 mm. The fatigue striations are found in
all the fracture surfaces. It can be noted in Fig. 8(a) that the crack
path is relatively flat at the mid-FCG stage for the untreated
sample, an average fatigue striation spacing of 0.77 μm was ob-
tained. However, after LP with laser pulse energies of 3 J, 5 J and
7 J, more multi-level fatigue steps appear while the fatigue path
becomes tortuous. In addition, the secondary cracks generate in
the striations, dissipating more energies. The average fatigue
striation spacings reduce to 0.38 μm, 0.31 μm and 0.18 μm, as
shown in Fig. 8(b)–(d).
While compared with crack initial stage, the fatigue striation
spacing at the mid-FCG stage increases significantly. It can be infer
that as the crack propagates, the load-bearing area reduces, re-
sulting in an increase of stress, and finally affects the width and
spacing of fatigue striation. While compared with untreated
sample, the reduction of fatigue striation spacing at the mid-FCG
stage indicates a significantly decrease of crack propagation speed,
and the reduction rate increases with an increase in laser power.
For the laser peened sample, the treated area covered a length of
15–30 mm, as a result, when the crack length reaches 25 mm, the
crack path still within the LP regions. Although the residual stress
releases with the increase of crack length, the microscopic mor-
phology shows that the effect of LP-induced residual stress on
inhibiting crack propagation still works.

Fig. 8. FCG path and fatigue striation pattern at middle stage of FCG on CT samples subjected to different laser pulse energies: (a) untreated, (b) 3 J, (c) 5 J and (d) 7 J.
 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176 175

Fig. 9. The region between FCG and transition fracture on CT samples subjected to different laser pulse energies: (a) untreated, (b) 3 J, (c) 5 J and (d) 7 J.

3.2.4. Transition region between FCG and final fracture region
Fig. 9 shows the effect of different laser pulse energies on
fracture morphology of transition region between the FCG and
final fracture region. Fig. 9(a)–(d) corresponds to the regions of C,
G, K, O in Fig. 3. Clear boundaries marked with yellow dotted lines
between the transition and FCG regions are identified. The FCG
region at the left side of the boundary mainly consists of fatigue
striations, while the final fracture area consists of micro porous
connected dimples.
Fracture morphology in the transition region of the untreated
sample in Fig. 9(a) exhibits fatigue steps with height difference.
The tendency of partial tear indicates a higher ΔK exists in the
transition region. Fig. 9(b)–(d) shows the fracture morphologies in
the transition region for laser peened samples with laser pulse
energies of 3 J, 5 J and 7 J, in which the boundary between FCG and
final fracture is not clear enough. Localized area presents a mixing
fracture characteristic by the combination of striations and dim-
ples. While compared with laser peened samples with 3 J, the laser
peened sample with 5 J shows more secondary cracks, which may
dissipate more energies. The laser peened sample with laser pulse
energy of 7 J exhibits more circuitous growing path, indicating a
harder crack propagation.
3.2.5. Final fracture region
Fig. 10 shows the final fracture morphologies of CT samples
with different laser pulse energies. Fig. 10(a)–(d) correspond to the
regions of D, H, L, P in Fig. 3. Static load rupture characteristics and
dimples can be observed. We can infer that extremely dislocation

Fig. 10. Final fracture on CT samples subjected to different laser pulse energies: (a) untreated, (b) 3 J, (c) 5 J and (d) 7 J.
176 J. Sheng et al. / Optics & Laser Technology 77 (2016) 169–176
stacking appears under external force, then large amount of micro
dimples generate in large plastic deforming region. The generated
dimples grow when suffered external force, and then gather to
form cracks.
Uniform equiaxed dimples can be observed in Fig. 10(a) for
untreated samples. The inclusions and second phase particles can
be found inside dimples. After LP with laser pulse energies of 3 J
and 5 J, the dimples size increases significantly. The inclusions are
clearly seen in larger size of dimples (Fig. 10 b and c), which in-
dicates that the inclusions effectively inhibit the FCG. After treated
by laser power of 7 J, the dimples size further increases. Due to the
effect of LP, stress state become complex and the dimples with
different sizes appear in the final fracture region. For instance,
small dimples distribute inside the large ones. A certain number of
slide steps and tear ridges can be found at the dimple boundary,
implying that the rupture happens after a larger plastically
deforming.
4. Conclusions
1. The fatigue striation spacings for laser peened samples at the
initial and middle stage of fatigue crack growth were decreased
compared with untreated samples, indicating that fatigue crack
growth rates were decreased by laser peening process. The
generated micro-fatigue-steps and secondary cracks after laser
peening are contributed to the inhibition of crack propagation.
2. At the initial stage of fatigue crack growth, more circuitous fa-
tigue crack growth paths were found. A “stop-continue” phe-
nomenon of crack propagation was discovered for laser peened
samples.
3. More fatigue steps appeared after laser peening at the middle
stage of fatigue crack growth. Secondary cracks were found
between the fatigue striations. The decreased fatigue striation
spacing after laser peening indicates a significantly decrease of
fatigue crack growth rate, and the effect of inhibition increased
with an increase in laser power.
4. From the morphology at the transition region, fatigue steps with
different heights were observed. Localized area presents a
mixing fracture characteristic of striations and dimples. The
laser peened sample with higher laser power showed more
secondary cracks and circuitous growing paths, which presents
a more effective inhibition of fatigue crack growth. In the final
fracture, the dimples size increased significantly after laser pe-
ening process.
Acknowledgments
The authors are grateful for the support provided by the Na-
tional Natural Science Foundation of China (Nos. 51405204 and
51175236), China Postdoctoral Science Foundation Funded Project
(Nos. 2014T70477 and 2013M540417), Jiangsu Planned Projects for
Postdoctoral Research Funds (No. 140l065B) and Advanced Talent
Foundation of Jiangsu University of China (No. 13JDG109).
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