Surface Mechanical Properties and Micro-Structure Evolution of 7075 Aluminum Alloy Sheet for 2-Dimension Ellipse Ultrasonic Vibration Incremental Forming: A Pretreatment for Laser Shock Peening

In this paper, a composite technique of ultrasonic incremental forming and laser shock peeing is proposed. The former process is mainly used for the manufacturing of complex-shaped sheet and strengthening coating that is prepared for subsequent laser treatment. The latter is applied for secondary surface reinforcement with ultra-high energy. This work focused on the novel ultrasonic incremental forming method and its effects on surface mechanical properties and micro-structure of a 7075 aluminum alloy. First, a kind of 2-dimension ellipse ultrasonic vibration incremental forming process and the unique double-mechanism method of sectionalized cooperative control of plastic deformation and mechanical performance were designed. Second, the single-point incremental forming, the longitudinal ultrasonic vibration incremental forming, and the 2 dimension ellipse ultrasonic vibration incremental forming were performed for the manufacture of conical components of 7075 aluminum alloy. Third, the Vickers micro-hardness testing results and images of the fracture morphology of the machined part for the novel technique confirm that softening mechanisms become dominant inside the metal sheet. Furthermore, a strengthening coating with excellent mechanical properties and a residual compressive stress field were created on its surface simultaneously. In a word, the research shows potential values of the proposed technique for the manufacture of aircraft panels of complex shape and excellent surface properties.