Advanced Ultrasonic Peening Process Training

Advanced Ultrasonic Peening Process Training

Focus: HFMI for Titanium, High-Strength Aluminium Alloys, Inconel & Advanced Materials LETS Global AB | Life Extension of Technical Structures Registered Office: Stockholm, Sweden | Org. No. 559546-7993 © 2025 LETS Global. All rights reserved.

Course Summary

This course provides advanced training on High-Frequency Mechanical Impact (HFMI) / Ultrasonic Peening for high-performance materials including titanium alloys, high-strength aluminium alloys, and nickel-based superalloys such as Inconel. Emphasis is placed on parameter optimization, treatment tailoring, and achieving targeted mechanical and fatigue-performance outcomes.

Target Audience

  • Aerospace structural and materials engineers
  • Fatigue, durability, and damage-tolerance engineers
  • Manufacturing and welding engineers in aerospace programs
  • MRO engineers and specialists in aircraft life extension
  • R&D engineers working with advanced metallic materials and joining technologies
  • Technical authorities responsible for certification and structural integrity

Required Qualifications / Background

  • Engineering degree or equivalent professional experience
  • Fundamental understanding of fatigue, fracture mechanics, and metallic material behavior
  • Familiarity with welded or mechanically joined aerospace structures
Prior experience with ultrasonic peening or HFMI is not required. The course is intended for professionals operating in high-performance or safety-critical environments.

Course Duration & Format

Duration: 3 days
  • Instructor-led training (in-person or virtual)
  • Advanced technical lectures with case studies
  • Practical demonstrations and hands-on parameter optimization
  • Group exercises and assessment
Typical daily duration: approximately 6–7 hours per day.

Day 1 — Fundamentals of HFMI & Material-Specific Behavior

1. Introduction to HFMI / Ultrasonic Peening

  • Principles of ultrasonic impact treatment
  • Residual stress generation
  • Weld toe geometry improvement
  • Fatigue life enhancement mechanisms

2. Material Science Foundations

  • Dislocation movement and plastic deformation
  • Hardness and material response
  • Microstructure sensitivity to HFMI
  • Comparison with conventional steel behavior

3. HFMI for Titanium Alloys

  • Titanium mechanical behavior and weldability
  • Residual stress challenges
  • Parameter guidelines for titanium HFMI
  • Avoiding overheating and micro-damage

4. HFMI for High-Strength Aluminium Alloys

  • Behavior of 2xxx, 6xxx, and 7xxx aluminium alloys
  • Age-hardening effects on HFMI performance
  • Managing high ductility and lower hardness
  • Optimal peening windows for aluminium structures

5. HFMI for Nickel-Based Superalloys (Inconel)

  • High-temperature strength and deformation behavior
  • Required peening energy levels
  • Achievable residual stress depths
  • Applications in demanding environments

Day 2 — Process Parameters, Treatment Optimization & Quality Control

1. Ultrasonic Peening Equipment & Control

  • Ultrasonic generators and tuning
  • Tooling variations
  • Frequency, amplitude, force, and contact duration
  • Multi-pass peening approaches

2. Optimization of HFMI Treatment Parameters

  • Achieving desired compressive stress levels
  • Selecting appropriate parameter combinations
  • Material-dependent adjustments
  • Stabilizing process outputs for repeatability

3. Desired Treatment Result Metrics

  • Residual stress magnitude and penetration depth
  • Surface refinement and weld toe radius improvement
  • Fatigue enhancement indicators
  • Identifying and preventing over-peening

4. Quality Assurance & Verification Techniques

  • XRD residual stress measurement
  • Surface profilometry and 3D scanning
  • Hardness testing
  • Documentation, traceability, and qualification

5. Practical Demonstration / Hands-On Session

  • Real-time parameter tuning
  • Sample treatment on titanium, aluminium, and Inconel
  • Post-treatment inspection and validation

Day 3 — Advanced Applications, Modelling & Case Studies

1. Fatigue & Performance Prediction for Advanced Materials

  • S–N curve modifications
  • Crack initiation vs propagation delay
  • Fracture mechanics considerations
  • Predictive modelling of HFMI performance

2. Application-Specific Optimization

  • Aerospace lightweight structures
  • Automotive and motorsport aluminium joints
  • Marine and offshore Inconel components
  • Additive manufacturing surface improvement

3. Troubleshooting & Failure Modes

  • Detecting under- and over-treatment
  • Correcting parameter drift
  • Addressing complex geometries

4. Industrial Case Studies

  • Titanium aerospace brackets
  • Inconel turbine housings
  • Aluminium 7xxx welded components
  • Mixed-material solutions

5. Group Exercise & Certification Assessment

  • Designing a parameter set for a chosen material
  • Interpreting residual stress and geometry data
  • Producing an optimization plan

Learning Outcomes

  • Apply HFMI to high-performance materials
  • Optimize treatment parameters for target results
  • Validate and document high-quality HFMI treatments
  • Predict fatigue benefits for advanced materials
  • Troubleshoot treatment issues and process deviations
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