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INNOVATIONS IN SHOT PEENINGcommon blast hose delivery system with a highly specializednozzle/lance holder. This Tool Changer resembles andoperates as seamlessly as the Tool Changers used globally inmulti-axis machining centers.Imagine shot peening a turbine disc or maybe a complexblisk. Conventional peening nozzles have always beenadequate for easy line-of-sight surfaces, but the disc has bladeslots and a variety of small bores that require a Rotating Lancenozzle. Additionally, the part has hidden areas in the mainbore that need a non-rotating L-Shaped lance, requiring anozzle change. Or maybe it’s the complex blades of a blisk thatneed to be peened without distortion, requiring a two-nozzleblisk tool.If this describes your shot peening operation, then you’reno doubt familiar with stopping the process and entering thepeening cabinet to change nozzles. Maybe you need to checkthe alignment of the new nozzle and, most likely, run anAlmen strip test. All of the above steps create non-productive,non-revenue producing machine downtime. These actionsalso invite operator error to enter the equation.The Progressive Surface automated tool changer isthe game changer our industry has been seeking. The shotContinuedpeening process and related industry is nearly 100 years old.I can’t help but wonder what Mr. Almen would think of thetoday’s shot peening industry—from its humble beginningsof manually grit blasting automotive valve springs to thepeening of today’s complex aerospace components.Speaking of the past and future, is the new Tool Changerour industry’s equivalent to Marty McFly’s Hoverboard?(Reference: Back to the Future II)Two key Features of the Intelligent MachineCabinet-Mounted CameraThe Progressive Surface Automated Cell illustrated inthis article includes a cabinet-mounted camera interfaceddirectly to the two robot controllers. This is a valuable, errorproofing tool. The camera compares the part to be peened tothe associated image stored in its part program. If the partloaded does not match the stored image’s information, theprocess will not start and the attending operator is given analarm message. When the correct part is loaded, the cameracompares the part orientation and automatically adjusts therobot off-sets to match the exact part position. This featureeliminates nozzle/part collisions and lance nozzle breakage.Features of theProgressive SurfaceIntelligent Machine Two articulated industrial robots, eachwith a dedicated wall-mounted toolrack Two RLD (rotary lance drives), eachdedicated to a robot Two pressure pot media delivery units,dedicated to a robot, with closed-loopmedia and air pressure control withinfinite adjustments and settings Six changeable nozzles/lances with nolimit to the number of nozzles otherthan cabinet interior space Dual work stations: one for processingand one for loading ShotMeter velocity sensor that dropsfrom the ceiling to measure mediavelocity Robotic camera to check partnumber via unique features and partorientation/position8The Shot Peener Spring 2016The Progressive Surface Intelligent Machine

Our digital spraying unit materializes the stable andconstant rate spraying of both of steel/non-steel shot For the first time in the world, we achieved the stableand constant rate spray, including for shot peeningand thermal spray pretreatment of nonmagneticmedia such as ceramic shot, alumina, glass beads,etc., which were difficult to use for precise processingin the past. For the fine shot of smaller than 200μm, only we canprovide stable and constant volume spraying. Digitally controlled spray unit achieves stable intensityand surface roughness.5-2-24 Matsue Edogawa-ku Tokyo132-0025 mail:info@fujimfg.co.jp28/1 Serithai Road, Minbri, Bangkok 10510 ndex.htmlE-mail:info@fujiblastech-thai.comSpring 2016 The Shot Peener9

INNOVATIONS IN SHOT PEENINGContinuedwears. This Automation Plus feature provides very accuratemonitoring of the peening process to the point where manyusers are creating new shot peening specifications that greatlyextend the interval between Almen strip test runs.Note: For now and the foreseeable future, Almen stripswill still be used when setting up the initial peening programsand for machine verification.The Progressive Surface ShotMeterThe ShotMeterThe second Automation Plus feature is the ShotMeter.The ShotMeter is an optical sensor that accurately senses,measures and records the actual shot peening media velocity.For the system discussed in this article, the ShotMetersensing head is located in the ceiling of the peening cabinet,extending for easy robot access and retracting when not inuse. Once programmed, the robot will present the peeningnozzle to the sensing head and the media velocity will bemeasured and compared to the part program requirements.After the velocity comparison is complete, the peening cyclecan commence.The media velocity is almost like a fingerprint—the blasthose diameter and length create unique media velocity witheach different media flow and air pressure. Over time, thevelocity slowly changes as the hose wears. The same is truefor the blast nozzle. Virtually each and every nozzle type,length and internal diameter has a unique velocity with agiven media flow and air pressure parameter when the nozzleis new. The media velocity is altered as the nozzle slowlyThe Future of Shot Peening is NowIndustry practitioners and experts alike agree there is a needand desire to automate and error-proof the process. Manynaysayers have preached that the environment was too harshand dirty to house cameras and tool-changers. Until now, allof this was true.A new generation of Automated Shot Peening systemshave been designed and proven in the field. Maybe for yourapplication, automation starts with robotic or automatedpart loading. Maybe your requirements include in-processmedia changes to complete a part. Or, maybe your partgeometry and closing tolerances need more surface-specificpeening nozzles. In any of these examples, automation is theanswer and with the exciting new generation of shot peeningequipment, all is now possible. lThe Progressive Surface Intelligent Machineat MTU Aero Engines AGAbout Progressive SurfaceProgressive Surface is a global leader in the design andmanufacture of automated machinery and closed-loopprocess controls for shot peening, abrasive grit blasting,thermal spray coating, and ultra high-pressure waterjetstripping applications in the aerospace, energy, medical,military, and general manufacturing industries.The Progressive Surface Cabinet-Mounted Camera10The Shot Peener Spring 2016For more information, visit www.progressivesurface.com.

IPS.Innovative Peening SystemsFanuc CNC ControlledS SeriesRotary LanceFive Axis CNCComputer ControlledShot Peening MachinePart Capacity24” dia x 36” highL SeriesSix Axis CNCComputer ControlledShot Peening MachinePart Capacity48” dia x 48” highCNC is no longer exclusive to the Fortune 500Innovative Peening Systems2825 Simpson CircleNorcross, GA 30071770-246-9883Our affordable CNC machines allows every shot peener toeliminate manual nozzle setups. CNC offers exceptionalpart processing speeds, accuracy of peening and consistentquality of parts.Spring 2016 The Shot Peener11

PrOCESS rEVIEWJuliette Tricoire Sonats www.sonats-et.comUltrasonic Shot Peening:From Portable Systems to robotic Production LinesA robust process used by Automotive, Aerospace, Energy and Medical industriesTHE STrESSONIC Ultrasonic Shot Peening (USP)process is similar to conventional shot peening (CSP) in that itis a cold-working surface treatment. Both use media to impactthe surface of a mechanical part, generating a compressiveresidual stress layer and improving material mechanicalproperties. Both enhance fatigue life and resistance to stresscorrosion cracking.USP differs from conventional shot peening methodsby the way kinetic energy is provided to the shot. Instead ofusing a constant air flow, gravity or high-speed rotation ofa turbine, USP uses the acceleration of a vibrating surfacecalled a sonotrode. The frequency of vibration is within theultrasonic wave range (20 kHz), which explains the name ofthe technique.with USP at 7-9A/F19A compared to 118µin/3.0µm Ra in CSPwith same Almen intensity.)How It WorksA generator delivers a sinusoidal electric signal that excites apiezo-electric transducer to convert this electric energy intoa mechanical displacement. Since the vibration deliveredby the emitter is small, the vibration must be amplified by aseries of boosters in order to transmit enough kinetic energyto the sonotrode which is directly in contact with the peeningmedia.Between the sonotrode and the precise area to bepeened, a specific enclosure is designed. Thus, the media ishermetically contained in a controlled volume. Longitudinalvibrations of the sonotrode surface randomly disperse mediainto the treatment volume as molecules into a gas. Thisgas-like movement leads to a homogeneous treatment on allsurfaces of the part being treated. gas turbine fir tree peening with reduced dismantling andcomplete media containment throughout the peeningoperationSurface Roughness / Peening Intensity Ratio ConcernsIn critical applications where deep compressive stresses arerequired and surface roughness must be kept at a minimum,USP can be a viable alternative to conventional shot peeningtechniques.Due to the treatment hermeticity, media quantity isreduced to several grams and USP can thus be performedusing high-quality media—such as bearing-balls with highsphericity—that do not abrade component surface. Media witha larger diameter can be used to reach a high intensity, inducedeep compressive stresses and lower surface roughness. (Forexample: 11.8µin/0.3µm Ra obtained on a TA6V part peened12The Shot Peener Spring 2016Handheld Hermetic Peening for Downtime ReductionReducing downtime—and its related costs—is a major issuefor Aeroengine and Gas Turbine manufacturers and MROindustries when handling major repairs on assembled parts.Portable USP systems by SONATS are the solution forthese industries. On-site shot peening with USP eliminatesthe need to dismantle the component and eliminates the riskof media loss inside the component. Typical applications ofthis localized shot peening are: Fan disk blended areas, without engine extraction, leadingto a 80% reduction of repair cycle time in-situ peening of damaged helicopter blades that saved 220,000 per blade (See Avion Solution, Inc. article in TheShot Peener, Winter issue, page 36)StressVoyager portable USP equipment on a storage trolley

Spring 2016 The Shot Peener13

PrOCESS rEVIEWStresstonic USP dynamic treatment ofautomotive output shaftsAutomated Multi-Station Machines forLean ManufacturingAutomotive gear manufacturers have to maintain highproductivity while insuring an efficient and repeatable processto critical transmission parts. In this framework, major OEMsare utilizing USP automated machine integration in specificpart production lines, thereby ensuring lean manufacturingpreservation. Specifically in USP machines for gear peening,treatment is performed in dynamic mode to reach apre-determined takt time. For example, a 40s takt time with a4-station machine will produce 500,000 parts/year.USP machines have the following automated functions:robotized handling directly from the previous processoperation, media counting (in units or in grams), sonotrodesand media wear-out monitoring, operator warning whenlifetime is reached, automated media loading/unloadingfor each independent workstation, global supervisionand periodic quality report issuance. In lower productionrate applications, semi-automated solutions are solicitedwith manual handling of the part through easily accessiblewindows.Stressonic USP automated 4-station machinefor automotive output shafts14The Shot Peener Spring 2016Stresstonic USP tooling plate for automotive output shaftsOn multi-station production machines, the part toolingsystem includes a specific hermetic enclosure, part supportand positioning tailstock (see photograph above).The tooling systems are modular. They can be set upin any machine station, independently from part referencegroup.Process requirements for transmission parts are specificallydemanding. USP is preferred in critical applications, such ascarburized gears and 20MoCr4 steel shafts, when high surfacecompressive stresses need to be homogeneously inducedon the teeth flanks and teeth roots. USP is able to generate-1100MPa (145Ksi) surface compressive residual stresses whilemaintaining a low Ra value.Robotized CellsThe highest automated solution for USP process is thecomplete handling of the process by 6-axis robots. For thetreatment of aerospace blisks, for example, a recent USPimplementation included the global handling of the partand robotized enclosure positioning to perform treatmenton blades, disc central bore, and disc holes. The decision touse USP technology for the blisks was mainly motivated byits ability to generate very similar residual stress profiles onboth intrado and extrado sides of the blades, insuring theaerodynamics of the part without distortion. lAbout SONATSFounded in 1991, SONATS, Europe Technologies Group,is an innovative industrial company specializing in metalsurface treatments using a patented ultrasonic processtechnology called Stressonic . The company headquartersare located in Nantes, France. SONATS providesequipment, services and competencies throughout theworld through an international network.EMPOWERING TECHNOLOGIES INC., SONATSAmerican subsidiary, is located in Alabama and providesNorthern America with local process support andequipment after-sales services.

Robotic/CNCShot Peening EquipmentPortable/MobileSystemsComplete Turn KeyProcess includingProgramming, FixtureDesign, andDocumentationPatent PendingAlmen Fixture DesignEI Distributor forMagnaValves, AlmenGages and Stripswww.peentech.com261 Burnham Street, East Hartford, CT 06108860-289-4328Shot PeeningNDTMass Media FinishingAerospace, Military &Commercial ApprovalsFAA Repair StationsKJ1R272K (CT) &G89R878X (GA)On-site CapabilitiesSurface Enhancement (CT & GA)Nondestructive Testing (GA)www.peentech.com8 Eastern Park RoadEast Hartford, CT 06108860-289-43283117 Emery CircleAustell, GA 30168770-941-9573Established 1966Spring 2016 The Shot Peener15

AN INSIDEr’S PErSPECTIVEKumar Balan Engineer Empire Abrasive EquipmentVisions of the FuturePart two of a two-part series on the past, present and future of shot peening and blast cleaning from industry leaders,including Michael Brauss, Dominic Cimino, Jim Harrison, Scott Nangle, Alain Portebois, Jim Whalen and Ron WrightWELCOME TO PArT TWO of our discussion on“Visions of the Future” in the shot peening world. In Part One,we established the current status of our shot peening industrythrough interviews with Jim Whalen of Progressive Surface,Ron Wright and Alain Portebois of Wheelabrator, MichaelBrauss of Proto Manufacturing, Jim Harrison and DominicCimino of Curtiss-Wright/Metal Improvement Companyand Scott Nangle of Empire Abrasive Equipment Company.This eclectic group further enlightened me on their thoughtson where we are headed—let’s see what they had to say.The Next Generation of Peening EquipmentOur group of experts was unanimous in their opinion thatcomputer-controlled equipment—for better monitoring andcontrol of the peening process—was the most importantinnovation in the past 20 years. However, each member ofthis group had a slightly different picture of the future.“Progressive Surface has successfully experimented with‘intelligent’ machines that reduce set-up time in the field,” saidJim Whalen of Progressive Surface. To explain the concept ofintelligent machines, let’s use the auto industry as an example.In the last decade, the automotive industry has developedthe driver interface with safety features such as lane control,back-up cameras and collision avoidance systems. They haveconcentrated less on the traditional engine, drive train andsuspension. Similarly, Jim believes the shot peening machinesof the future will incorporate error-proofing, enhancedinternal communication and better process design, leadingto a clearer handle on the machine’s health. He summarized,“This in turn will result in a machine that will not just raisealarms when the process is off track, but will actually be a fewsteps ahead in working towards a fix.” Jim also raised a veryvalid concern: The challenge of finding personnel capable ofworking with these intelligent systems.16The Shot Peener Spring 2016Alain Portebois and Ron Wright of Wheelabrator seethe future a bit differently, though still leading to a similarconclusion. “Peening equipment design is heading in thedirection of a machine tool, much like a machining center.There is a growing similarity in accuracy, repeatability andcontrols intuition,” said Ron.Alain added, “Aerospace customers of Wheelabratorare favoring offline programing techniques to optimizemachine utilization.” Alain also said that part programs areprepared well ahead of time with 3D models of components.Wheelabrator R&D is working on techniques to improve theefficiency of existing media propulsion techniques in bothwheel- and air-type systems.Scott Nangle of Empire Abrasive Equipment Companyalso believes in connectivity. “We are already seeing oursophisticated customers connect their peening machineswith the rest of their production machinery and processes.This is not just for validation and transfer of peening results,but also to put their already available electronic footprint toproductive use,” said Scott. He feels the end goal is to makethe diagnostics more intuitive, leading to earlier predictabilityof maintenance. This is especially valuable for aerospace andmedical components.Jim Harrison of Curtiss-Wright/Metal ImprovementCompany explained his vision relating to component design.“The future is about building shot peening process recipes aspart of the component design. This will greatly reduce set-uptime, costs and add better value to the entire operation. Thedesign of aerospace components will follow tighter normswith the use of finite element analysis,” said Jim.Michael Brauss of Proto Manufacturing believes X-RayDiffraction (XRD) will eventually become part of the peeningspecification. “More companies are following their Almenstrip validations with our XRD services,” said Mike.

A Cut Above1666 Enterprise ParkwayTwinsburg, OH 44087The advantage of Premier Cut Wire ShotHighest Durability Due to its wrought internal structure withalmost no internal defects (cracks, porosity, shrinkage, etc.) thedurability of Premier Cut Wire Shot can be many times that ofother commonly used peening mediaAsCutImproved Consistency Highest consistency from particleto particle in size, shape, hardness and density compared tocommonly used metallic media.Highest Resistance to Fracture Premier Cut Wire Shotmedia tends to wear down and become smaller in size ratherthan fracturing into sharp-edged broken particles, which maycause surface damage to the part.NormalConditioningLower Dust Generation Highest durability equals lowestdust levels.Lower Surface Contamination Cut Wire Shot doesn’thave an Iron Oxide coating or leave Iron Oxide residue — partsare cleaner and brighter.Improved Part Life Parts exhibit higher and more consistentlife than those peened with equivalent size and hardness caststeel shot.SpecialConditioningSubstantial Cost Savings The increase in useful life ofPremier Cut Wire Shot results in savings in media consumptionand reclamation, dust removal and containment, surfacecontamination and equipment maintenance.Premier Shot Cut Wire Products forAutomotiveMedicalAerospace Applications Worldwide(330) 405-05831666 Enterprise Parkway,Twinsburg, Ohio 44087Spring 2016 The Shot Peenerpremiershot.com 17

AN INSIDEr’S PErSPECTIVEContinuedSpecifications and ConformanceDominic Cimino of Curtiss-Wright/Metal ImprovementCompany is well-informed on specifications. He said, “We don’tsee a relaxation in specifications. We see them getting tighteras companies spread their operations over multiple locations.”Jim Whalen said, “Specifications have been harmonizedt

Electronics Inc. For a free subscription of the The Shot Peener, go to www.theshotpeenermagazine.com The Shot Peener 56790 Magnetic Drive Mishawaka, Indiana, 46545 USA Telephone: 1-574-256-5001 www.theshotpeenermagazine.com The editors and publisher of The Shot Peener disclaim all warranties, express or implied, with respect to