Fatigue Damage in Shot-Peened Al7075-T6 Alloy: Correlation Between Acoustic Emission Spectra and Fractographic Analysis

Shot-peening treatments improve the fatigue performance of mechanical components thanks to the surface modifications introduced and mainly due to the residual compressive stresses present in the layer of material near the shot-peened surface. There is no unanimous agreement in scientific literature regarding the kinetics of the damage process. However, it is generally accepted that, due to morphological and microstructural changes in the shot-peened layer, the material is more prone to early crack initiation, the propagation of which is then significantly slowed down or even stopped by the local stress field. This work focuses on applying the acoustic emission (AE) technique to detect fatigue crack initiation and propagation in shot-peened Al-alloy components. The analysis is conducted on Al-7075-T6 alloy, subjected to different shot-peening conditions and fatigue tested under alternating four-point bending. The results from the AE analyses are then correlated with a fractographic analysis. For all shot-peening conditions investigated, acoustic emission consistently indicated probable crack nucleation at approximately two-thirds of the total fatigue life, followed by a significant damage accumulation phase prior to dominant crack propagation. The final increase in acoustic activity coincided with the measurable loss of stiffness, confirming the onset of accelerated crack growth leading to fracture. The results demonstrate that, despite some experimental challenges, AE monitoring has the potential for the early detection of damage initiation.