This article summarizes the development of laser peening without coating (LPwC) during the recent quarter century. In the mid-1990s, the study of LPwC was initiated in Japan. The objective at that time was to mitigate stress corrosion cracking (SCC) of structural components in operating nuclear power reactors (NPRs) by inducing compressive residual stresses (RSs) on the surface of susceptible components. Since the components in NPRs are radioactive and cooled underwater, full-remote operation must be attained by using lasers of water-penetrable wavelength without any surface preparation. Compressive RS was obtained on the top-surface by reducing pulse energy less than 300 mJ and pulse duration less than 10 ns, and increasing pulse density (number of pulses irradiated on unit area). Since 1999, LPwC has been applied in NPRs as preventive maintenance against SCC using frequency-doubled Q-switched Nd:YAG lasers (λ = 532 nm). To extend the applicability, fiber-delivery of intense laser pulses was developed in parallel and has been used in NPRs since 2002. Early first decade of the 2000s, the effect extending fatigue life was demonstrated even if LPwC increased surface roughness of the components. Several years ago, it was confirmed that 10 to 20 mJ pulse energy is enough to enhance fatigue properties of weld joints of a structural steel. Considering such advances, the development of 20 mJ-class palmtop-sized handheld lasers was initiated in 2014 in a five-year national program, ImPACT under the cabinet office of the Japanese government. Such efforts would pave further applications of LPwC, for example maintenance of infrastructure in the field, beyond the horizons of the present laser systems.

Laser peening without coating (LPwC) involves irradiating materials covered with water with intense laser pulses to induce compressive residual stress (RS) on a surface. This results in favorable effects, such as fatigue enhancement; however, the mechanism underlying formation of the compressive RS is not fully understood. In general, tensile RS is imparted on the surface of the material due to shrinkage after heating by laser irradiation. In this study, we assessed the thermo-mechanical effect of single laser pulse irradiation and introduce a phenomenological model to predict the outcome of LPwC. To validate this model, RS distribution across the laser-irradiated spot was analyzed using X-ray diffraction with synchrotron radiation. In addition, the RS was evaluated across a line and over an area, following irradiation by multiple laser pulses with partial overlapping. Large tensile RSs were found in the spot irradiated by the single pulse; however, compressive RSs appeared around the spot. In addition, the surface RS state shifted to the compressive side due to an increase in overlap between neighboring laser pulses on the line and over the area of irradiation. The compressive RSs around a subsequent laser spot effectively compensated the tensile component on the previous spot by controlling the overlap, which may result in compressive RSs on the surface after LPwC.

The purpose of the present study was to verify the effectiveness of dry laser peening (DryLP), which is the peening technique without a sacrificial overlay under atmospheric conditions using femtosecond laser pulses on the mechanical properties such as hardness, residual stress, and fatigue performance of laser-welded 2024 aluminum alloy containing welding defects such as undercuts and blowholes. After DryLP treatment of the laser-welded 2024 aluminum alloy, the softened weld metal recovered to the original hardness of base metal, while residual tensile stress in the weld metal and heat-affected zone changed to compressive stresses. As a result, DryLP treatment improved the fatigue performances of welded specimens with and without the weld reinforcement almost equally. The fatigue life almost doubled at a stress amplitude of 180 MPa and increased by a factor of more than 50 at 120 MPa. DryLP was found to be more effective for improving the fatigue performance of laser-welded aluminum specimens with welding defects at lower stress amplitudes, as stress concentration at the defects did not significantly influence the fatigue performance.

Laser peening without coating (LPwC) using a palmtop-sized microchip laser has improved the residual stresses (RSs) and fatigue properties of A7075 aluminum alloy. Laser pulses with a wavelength of 1.06 μm and duration of 1.3 ns from a Q-switched Nd:YAG microchip laser were focused onto A7075 aluminum alloy samples covered with water. X-ray diffraction revealed compressive RSs on the surface after irradiation using laser pulses with an energy of 1.7 mJ, spot diameter of 0.3 mm, and density of 100–1600 pulse/mm². The effects were evident to depths of a few hundred micrometers and the maximum compressive RS was close to the yield strength. Rotation-bending fatigue experiments revealed that LPwC with a pulse energy of 1.7 mJ significantly prolonged the fatigue life and increased the fatigue strength by about 100 MPa with 10⁷ fatigue cycles. The microchip laser used in this study is small enough to fit in the hand or be mounted on a robot arm. The results may lead to the development of tools that extend the service life of various metal parts and structures, especially outdoors where conventional lasers are difficult to apply.