Winter 2014 Volume 28, Issue 1 | ISSN 1069-2010 Shot Peener The Sharing Information and Expanding Global Markets for Shot Peening and Blast Cleaning Industries Scott Hatfield 2013 Shot Peener of the Year Scott Hatfield is the Laser Peening Is On the Move author of the new An Almen Mini-Strip SAE medical implant Validation Study specification and leader of Medtronic’s The “Peenability” of shot peening validation Steel Components program 2 The Shot Peener | Winter 2014 Winter 2014 | CONTENT 6 10 His leadership in the development of a new SAE Kelly McClurg, medical implant specification Materials Engineer with and a validated shot peening Avion Solutions, presented the results of the program at Medtronic Spinal has first phase of her mini-strip validation program earned Scott Hatfield the 2013 at the U.S. Shot Peening Workshop. Shot Peener of the Year award. 14 Mobile laser peening by Metal Improvement Company was used to process the lower wing attachment lugs of 16 in-service F-22 fighter jets. VERTEX SELECT® Reconstruction System Courtesy Medtronic, Inc. 12 32 High Velocity Oxygen Fuel Process Control Industry News Study with Almen Strips News from Ervin Industries and Nadcap. Almen strips are getting attention in the field of High 36 Velocity Oxygen Fuel (HVOF) coating sprays. Shot Peening in the News 18 The local newspaper in Hartford, Connecticut recently MIT Researchers Discover Self-Healing Metal published an article on Peening Technologies of MIT researchers thought that the test results must be a Connecticut. mistake. Is it possible that a crack under tension can heal 40 itself? Lessons in Intensity and Coverage 24 Jack Champaigne explains why intensity isn’t dependent on exposure time. ‘Peenability’ of Steel Components Dr. David Kirk’s article describes the basic relationships 42 that exist between service conditions, steel composition An Interview with Surface International and ‘peenability’. THE SHOT PEENER Sharing Information and Expanding Global Markets for Shot Peening and Blast Cleaning Industries Winter 2014 | The Shot Peener 3 OPENING SHOT by Jack Champaigne | Editor | The Shot Peener Six Things I Learned While Working on the THE SHOT PEENER This Shot Peener Editor Jack Champaigne Associate Editor 1.Scott Hatfield is a true “Shot Peening Subject Kathy Levy Matter Expert.” Scott was nominated as our 2013 Shot Peener of the Year because of his work Publisher on the SAE Surface Enhancement Committee and Electronics Inc. his leadership of a shot peening validation project at Medtronic. I’ve gotten to know and appreciate For a free subscription of the Scott through our work on the SAE committee, but The Shot Peener, go to I didn’t understand the depth of his contribution www.theshotpeenermagazine.com to Medtronic’s shot peening program until we interviewed him for the article on page six. Now I’m The Shot Peener even more pleased that he was given the award. 56790 Magnetic Drive Mishawaka, Indiana, 46545 USA 2.Almen mini-strips and ultrasonic peening are ideal together. I was pleasantly surprised JACk CHAMPAIGNE Telephone: 1-574-256-5001 to learn about Kelly McClurg’s work with mini-strips www.theshotpeenermagazine.com and ultrasonic peening (page 10). This is a novel, but ideal, application since both products are well-suited for small, localized repairs in the field. The editors and publisher of The 3.A new use for Almen strips. I have long championed the use of Almen test Shot Peener disclaim all warranties, strips for the abrasive blast cleaning industry as a quality assurance tool. Now express or implied, with respect to a new application is being researched for the High Velocity Oxygen Fuel (HVOF) advertising and editorial content, process (page 12). and with respect to all errors or omissions made in connection with 4.Researchers at MIT have discovered something surprising that could advertising or editorial submitted for affect our industry. Is our industry heading for obsolescence? Can self- healing metals replace the need for residual compressive stresses imparted by shot publication. peening? Are we dinosaurs waiting for a meteor impact? Read about the fascinating Inclusion of editorial in The Shot research done at MIT on page 18. Peener does not indicate that The 5.Dr. Kirk never ceases to amaze me. I remember meeting Dr. Kirk in 1993 at Shot Peener management endorses, the International Conference on Shot Peening which he organized at Oxford recommends or approves of the University. He was a professor at Coventry University at that time. I was mesmerized use of any particular commercial by his skill at explaining processes and concepts. His article in this issue of The Shot product or process or concurs with Peener (page 24) serves as yet another example of his ability to explain complex the views expressed in articles theories to laymen. His explanation of graphs on S-N curves (stress versus number of cycles) and residual stress profiles is particularly informative. contributed by our readers. Articles in The Shot Peener may not 6.I could write an article on intensity and coverage for every issue of The be distributed, reprinted in other Shot Peener. I have a file folder of emails from engineers and shot peening technicians with questions on intensity, coverage, saturation curves and more. The publications, or used on the internet Shot Peener staff likes to share new and different topics but many people struggle without the written permission of with these concepts, especially when they try to put them into practice on the shop The Shot Peener. All uses must credit floor. I plan to share more of these “problem and solution” articles in the future. The Shot Peener. 4 The Shot Peener | Winter 2014 Prepared for performance High precision peening solutions Whether you are peening Wheelabrator will deliver the large areas with centrifugal right solution to meet your wheels or targeting needs. specifi c areas with CNC automated airblast nozzles, Contact us to fi nd out how. US: 800-544-4144 • Canada: 800-845-8508 • [email protected] www.wheelabratorgroup.com Norican Group is the parent company of DISA and Wheelabrator. Winter 2014 | The Shot Peener 5 New_ad_8.25x11_Fall_2009_V2.indd 1 18.09.2009 09:29:03 2013 SHOT PEENER OF THE yEAR By Kathy Levy | InfoProse | [email protected] Specification for Success SCOTT HATFIELD is self-deprecating and quick to was right, he and Mark met an OEM at the trade show that give others credit for a job well done. But ask him about his was willing and capable of developing a customized robotic involvement with the shot peening program at Medtronic shot peening system that could meet the FDA’s demands for Spinal and his contributions to its success become evident. a controllable and repeatable shot peening process. Another His leadership in the development of a new SAE medical benefit of the workshop was that the Medtronic engineering implant specification and a validated shot peening program staff was exposed to every aspect of a controlled shot peening has earned him the 2013 Shot Peener of the Year award. process. Eventually, Medtronic’s shot peening technicians and The Medtronic project began in 2005 when Scott’s inspectors from the Indiana and Puerto Rico facilities would boss, Mark Pelo, asked Scott to develop a FDA-compliant receive training and earn their Shot Peening Certifications. shot peening process for a new spinal screw. Medtronic was Scott has achieved EI’s Level Three Shot Peening Certification, outsourcing most of their shot peening at that time, but they the highest certification available, and is now a Specialized recognized that it would be easier to control the work if it was Instructor for the EI Shot Peening Workshop. done on their shop floor. Mark also wanted to duplicate the shot peening operation at their facility in Humacao, Puerto Rico. Creating Discipline Through Documentation Scott had limited knowledge of shot peening having At the beginning of the project, Scott started working on a worked in aerospace and automotive machine shops before guidance document for the shot peening machine technicians. starting at Medtronic in 2001. While working at a machine He began reading shot peening specs for reference. Scott shop, he saw the request for “shot peening” on a print and became a regular attendee at the Shot Peening Workshops began researching it. When Mark approached him, Scott where he had conversations with Jack Champaigne, President already knew enough to question if the tumblast machine of EI and Chairman of the Society of Automotive Engineers on the plant floor was the right equipment for the task. Surface Enhancement Committee (SAE SEC), about how In addition to probable limitations in equipment, Scott parts of aerospace and automotive specs weren’t applicable to recognized that engineers and machine operators needed medical implant manufacturing. “There were bits and pieces in-depth shot peening training, that he needed to create of useful information in aerospace and automotive specs but training documentation, and that the process would need I wanted a ‘one-stop’ document,” said Scott. “Jack invited testing. “I wanted a program that I was willing to put my me to join the committee and I accepted with the idea that name on,” Scott said. membership could help me improve our internal document and lead to a new SAE standard for our industry.” Jack Building the Foundation with Equipment encouraged Scott to write the specification and Scott started and Education on what would become “SAE J3020 for Medical Device Shot Scott, Mark, and several other Medtronic engineers went Peening.” His intent was to write a standard that adequately to the 2006 Electronics Inc. (EI) Shot Peening Workshop defined best practice methodology for medical device shot and Trade Show. Initially, Scott wanted to talk with other peening. workshop attendees to see if he was correct in thinking In 2013, only two years after he started on the specification, that a tumblast machine couldn’t support a validated shot Scott presented the final draft of J3020 to the committee and peening process. Fortunately, at the same time he learned he submitted a request for a ballot. “He worked diligently on this Scott Hatfield Manufacturing Engineer, Medtronic Technology Engineering Group Job Responsibilities include: • Shot Peening and Abrasive Finishing Subject Matter Expert • Implementation of New Technologies Pertaining to Process Improvements • New Product DRM Analysis (Design for Reliability and Manufacturability) • New Product Process Design and Development • New Product Initial Cost Estimating 6 The Shot Peener | Winter 2014 Winter 2014 | The Shot Peener 7 2013 SHOT PEENER OF THE yEAR Continued spec and it went through SAE in only two years, which is very Shot Peener of unusual,” said Jack. Scott credits the successful development of the spec to the committee. “The time frame wouldn’t the year Award have been possible without the dedication of the group and Jack’s willingness to allot time in every meeting to work on refining the specification,” said Scott. Jack doesn’t completely Since 1992, The Shot Peener magazine has given “The Shot agree with Scott’s assessment. “It’s great having Scott on our Peener of the Year” award to individuals in our industry that committee. He brings a discipline to our meetings that helps have made significant contributions to the advancement us work on many document topics from media to intensity of shot peening. We’ve listed the year of the award, the and coverage,” Jack said. recipient and their place of employment at the time they Medtronic has also shown unselfish support for the received the award. new document since J3020 will be applicable to all medical implant manufacturing. “I am proud to say that Medtronic 2013 Scott Hatfield Medtronic Spinal is committed to advancing shot peening practices as 2012 Hali Diep Boeing Research and demonstrated by their continued support of my involvement Technology in SAE,” said Scott. 2011 James Kernan U.S. Army Aviation and Missile Research, Development and Validation Through Testing Engineering Center After the shot peening machines were completed (one for 2010 Herb Tobben Clemco Industries the Indiana Medtronic facility and one for the Puerto Rico 2009 Michelle Bandini Peen Service plant), Scott initiated life cycle testing on shot-peened spinal 2008 Holger Polanetzki MTU Aero Engines screws to validate and optimize their shot peening practices. 2007 Ken l’Anson Progressive Technologies “Validation increased our confidence that the shot peening 2006 Kumar Balan Wheelabrator Group, Ontario process and the resulting increase in fatigue resistance was Dr. John Cammett Materials Engineeering dependable and repeatable and would improve product Division, Naval Aviation Depot reliability,” said Scott. The testing program has had a “trickle 2005 Marsha Tufft GE Aircraft Engines up” effect from the shop floor—design engineers now call Helmut Wohlfahrt Technical University of Scott and ask him about incorporating shot peening in a part. Braunschweig The design engineers can take advantage of Medtronic’s large 2004 Walter Beach Peening Technologies database of shot peening test results. Dr. Katsuji Tosha Meiji University 2003 Paul Prevey Lambda Research Shot Peening: The Highlight of a Medtronic Tour Dr. Niku-Lari IITT International Shot peening has not only been given a place on Medtronic’s 2002 David Francis Metal Improvement Company shop floor, it’s now a highlight of their plant tours. The Shaker Meguid University of Toronto company is proud of their cost savings from bringing shot 2001 Dr. David Kirk Coventry University, U.K. peening in-house. “Even with the purchase of two robotic Dale Lombardo GE Aircraft Engines shot peening machines and the time and other resources we’ve Bill Miller The Boeing Company invested in a validated shot peening program, our in-house 2000 Jonathan Clarke Delta Air Lines program is still less expensive than outsourcing,” said Scott. Lothar Wagner Technical University of Cost savings aren’t the only reasons Medtronic is proud Brandenburg of their shot peening program. “Through Scott’s commitment 1999 Andre Levers British Aerospace Airbus and leadership, Medtronic has a world-class shot peening 1998 Wolfgang Kugelstrahlzentrum Aachen program that is validated in the medical community,” said Linnemann Mark Pelo. “Clearly, Medtronic and the shot peening industry 1997 Dr. R. Kopp Institute Metal Forming of RWTH have benefited from Scott’s commitment to shot peening 1996 Dr. M.C. Sharma Maulana Azad College of technology,” he added. Technology Scott is still very involved in the day-to-day concerns of 1995 Dr. Kisuke Iida Meiji University shot peening and anything to do with shot peening validation. 1994 Charlie Barrett Metal Improvement Company He plans to continue his involvement with SAE SEC even 1993 Pete Bailey GE Aircraft Engines after the specification is published. l Bob Thompson GE Aircraft Engines Jim Whalen GE Aircraft Engines 1992 Charlie Mason Menasco Aerospace Ltd. 8 The Shot Peener | Winter 2014 IPS.... Innovative Peening Systems Fanuc CNC Controlled S Series Five Axis CNC Rotary Lance Computer Controlled Shot Peening Machine Part Capacity 24” dia x 36” high L Series Six Axis CNC Computer Controlled Shot Peening Machine Part Capacity 48” dia x 48” high CNC is no longer exclusive to the Fortune 500 Our affordable CNC machines allows every shot peener to Innovative Peening Systems eliminate manual nozzle setups. CNC offers exceptional 2825 Simpson Circle part processing speeds, accuracy of peening and consistent Norcross, GA 30071 quality of parts. 770-246-9883 Winter 2014 | The Shot Peener 9 PRODuCT VALIDATION STuDy Avion Solutions | www.avionsolutions.com Mini-Strip Research Presented at u.S. Shot Peening Workshop kELLy MCCLuRG presented components. (Avion Solutions has been validated by the U.S. the results of the first phase of her Army as an Approved Source for the Ultrasonic Shot Peening mini-strip validation program at the Process.) Avion creates enclosures called “end effectors” that 2013 U.S. Shot Peening Workshop. mate the sonotrode head of the Stresstonic to the section of Ms. McClurg is a Materials Engineer for a component that receives the ultrasonic treatment. The end Avion Solutions, Inc. in Huntsville, effector becomes a small peening chamber around the repair Alabama. Avion Solutions provides area. “We need to make a new end effector for each area of specialized engineering, logistics, the component to be peened. When we change the design of software development, and technical the end effector, we are changing a shot peening parameter services to the U.S. Army’s aviation and we need to validate the intensity because of the changed community. Kelly McClurg parameter,” said Ms. McClurg. “Mini-strips offer a fast and Ms. McClurg was introduced to Materials Engineer accurate solution.” Almen mini-strips when a colleague Avion Solutions Inc. Ms. McClurg’s presentation at the 2013 Electronics Inc. brought her a sample of the strips U.S. Shot Peening workshop was titled “Mini-Almen Strips: A from an Army Aviation Association of America convention. Promising New Technology.” Her presentation included: Mini-strips are 1" x .125" (25.4 mm x 3.175 mm) Almen • Development of a correlation between full-size Almen strips that can be attached with double-sided tape directly strips and mini-strips arc heights on a test component or simulated fixture. Their size makes • Performance comparison between full-size Almen them ideal for measuring intensity in small or hard-to-reach strips and mini-strips areas like dove-tail slots in jet engine disks, gear roots, and • Intensity validation study along altering geometry the internal bore of springs, without making a complicated (a helicopter tail rotor blade pitch horn was used) test fixture. Avion is currently using shaded strips which • Mini-strip saturation curve study involves a laborious masking process. Ms. McClurg • The benefits of using mini-strips including validation recognized that the mini-strip could quickly and accurately of intensity on an angled incline, elimination of complex obtain intensity measurements. “I conducted this study to get and costly test fixtures, and intensity confirmation a better understanding of intensities in the small areas of a available in areas unattainable with full-size Almen strips component. When using shaded Almen strips, we are only The convenient and easy-to-use mini-strips can be the getting an arc height. If we change the parameters of the ideal complement to Avion’s portable ultrasonic shot peening shot peening procedure, then this arc height is no longer a processes. “The results of this first study are very promising,” confirmation of intensity as the arc height can fall anywhere said Ms. McClurg. “If we continue to see good results through along the saturation curve,” she said. the conclusion of the study, mini-Almen strips will replace Avion utilizes ultrasonic shot peening with the portable our use of shaded Almen strips and allow for increasingly SONATS StressVoyager® for small, localized repairs on helicopter accurate measurements of intensities in small areas, rather than just arc heights.” Avion Solutions has sent these findings to the U.S. Army for approval to use mini-strips in qualifying intensity on a Helicopter repair for a Critical Safety Item. l Tail Rotor Blade Pitch Horn more information Almen Mini-Strips: Visit www.electronics-inc.com or call Electronics Inc. at 1-800-832-5653 or (574)256-5001 Mini-Strip “A Promising New Technology”: Download the PowerPoint presentation from the library at End www.shotpeener.com Effector Avion Solutions: Visit www.avionsolutions.com or call (256)327-7144 10 The Shot Peener | Winter 2014