A machining tool incorporates a shaft having a first end configured to fit into a machining collet. A cutting portion extends from a second end of the shaft. A residual stress inducer is located between the first and second ends and includes a torsion element joined to the shaft at a connection end. A carbide tip is present on a free end opposite the connection end and the torsion element is configured such that a selected rotational speed, altered from a normal cutting speed, causes the carbide tip of the torsion element to contact a workpiece surface.

A robotised hammering method for hammering a weld seam (C) made on a base surface (S) of a metal workpiece (V) using a robotised system (32), comprising the following steps:controlling the robotised system (32) provided with an effector (35; 38) carrying a scanning tool (30) in such a way as to follow, with the scanning tool (30), an initial path along the weld seam (C), said initial path having been determined from the digital model of the workpiece or from the actual workpiece,acquiring, by means of the scanning tool (30), along the initial path, local data concerning the elevation and position of the weld seam and of the area or areas of the base surface close to the weld seam,calculating, from the elevation and position data acquired in this way and from the initial path, a corrected path, andcontrolling the robotised system (32) provided with an effector (40; 38) carrying a hammering tool (41) to hammer the weld seam along this corrected path.

Systems and method for tool path approximation may comprise approximating the outer surface of a part to be worked. The outer surface may be approximated by a plurality of airfoils. Moreover, the system and methods approximate a tool path based on a cutting tool and convert the tool path to accommodate a non-cutting processing tool. The tool path may be implemented on a computer numerically controlled machine that is configured to control a flexible fork peening tool.

Aspects are directed to removing a portion of a component that includes wear to generate a void in the component, where a material of the component has a first microstructure, depositing a filler material in the void, subjecting the filler material to a cold working technique to compress the filler material, and applying a heat treatment to cause the filler material to have a second microstructure that is matched to the first microstructure. Aspects are directed to a case of an engine, including: a first portion with a first material that has a first microstructure, and a second portion with a second material that has a second microstructure, where the second microstructure is matched to the first microstructure, where the second material includes a plurality of layers, and where at least one layer of the plurality of layers includes a compressive residual stress.

A process or method for forming a stainless steel weldment comprises steps including rolling a plate to form a cylindrical shell with an open butt joint or seam, welding the butt seam to close the seam, hard rolling the weld seam region including the adjacent heat affected zones in the base material, and peening the weld seam region. The weld seam region is peened in multiple successive and wider passes to progressively produce wider peening strips or regions along the weld lines. The weld may be a full penetration double-V type groove weld with double weld bevels. The welding process may include first forming the exterior weld bevel following by forming the interior weld bevel. The foregoing fabrication process converts residual tensile stress fields on the exterior of the shell weldment to compressive stress fields less susceptible to the adverse effects of stress corrosion cracking.

In some examples, a material may be subject to shot peening of a relatively long duration to improve cavitation erosion resistance of the material. For example, the material surface may be shot peened to cause grain reduction and an increase in hardness to a depth of 60 m or more, while the surface remains relatively smooth. As one example, the method may include treating a surface of austenitic stainless steel by impacting the surface with shot media for a treatment duration of 15 to 40 minutes at a shot peening intensity corresponding to an Almen strip type A intensity of 5A to 10A.

A method and apparatus for processing a metallic workpiece with defined edges (e.g., a gear) comprises media blasting of the workpiece by directing a first media against exposed surfaces on the workpiece to increase the root strength of the gear, the blasting causing the defined edges to be radiused or mushroomed, ceasing the media blasting, loading the workpiece into a finishing apparatus, and subjecting the workpiece to a finishing process with a second media, the exposed surfaces on the workpiece being subjected to the finishing process to reduce the radiused edges on the workpiece created from the media blasting. The process of moving the workpiece to the spindle-finishing apparatus from the media blasting may be performed automatically by a machine. Once the workpiece has been subjected to the finishing process with the second media, it may be removed from the spindle-finishing machine, washed, and rinsed with rust inhibitor whereby wear properties of the workpiece are enhanced.

A guard for a part to be shot-blasted and having an axis of revolution, the guard including: a cover and a chamber shaped for receiving the part to be shot-blasted; the chamber having at least one planar section with a shape matching at least one planar section of the cover; two side guards mounted on the part to be shot-blasted and having one degree of freedom relative to the chamber and the cover, wherein the cover, the chamber and the two side guards form a box for sealing the shot, the box including a window for projecting the shot, the surface of which matches a portion of a surface of the chamber.

A method for controlled peening includes forming a surface layer on a workpiece by impacting a surface with a tool wherein the tool is under control to form compressive residual stresses in the surface layer. A system for peening a workpiece includes a tool configured to vibrate and an effector operatively connected to control the tool. The tool includes a peening surface. The tool is configured to cause controlled impact between the peening surface and a surface of a workpiece to form a surface layer of the workpiece with compressive residual stresses. The effector is configured to move the tool in multiple axes.

A method and apparatus for processing a metallic workpiece with defined edges (e.g., a gear) comprises media blasting of the workpiece by directing a first media against exposed surfaces on the workpiece to increase the root strength of the gear, the blasting causing the defined edges to be radiused or mushroomed, ceasing the media blasting, loading the workpiece into a finishing apparatus, and subjecting the workpiece to a finishing process with a second media, the exposed surfaces on the workpiece being subjected to the finishing process to reduce the radiused edges on the workpiece created from the media blasting. The process of moving the workpiece to the spindle-finishing apparatus from the media blasting may be performed automatically by a machine. Once the workpiece has been subjected to the finishing process with the second media, it may be removed from the spindle-finishing machine, washed, and rinsed with rust inhibitor whereby wear properties of the workpiece are enhanced.