Laser peen forming is a powerful, laser-based method of shaping metal parts to specific geometric configurations.
We use finite element modeling and precision laser peening patterns to shape metal into precise contours and angles.
The process is predictable and precise. Laser peen forming can be used for initial part fabrication, repair and replacement of complex curved parts, or to straighten tubes, rods, and flat surfaces with precision.
Turning complex curves and shapes into fully formed components
Using laser peen forming opens up so many possibilities for metal part fabrication and repairs. An aluminum ship hull, for example, requires a precisely curved patch that must meet arduous environmental and safety standards. Manufactured tubing must be straightened to an order of magnitude beyond normal fabrication standards for a demanding application. The combination of FEA modeling and precise application of laser peening can shape, re-shape, or straighten components for mission-critical applications.
Laser peen forming is possible thanks to the predictable distributions of plastic strain imparted by the laser peening process. Because these distributions are readily responsive to today’s analytical modeling tools, we can use Finite Element Analysis (FEA) to simulate the imparted plastic strain along with the elastic response of the surrounding material. This allows accurate, scalable predictions that translate into a vast array of unique curvatures and shapes.
Materials processed with laser peen forming include aluminum alloys of varying thicknesses (0.1 inch to 0.5 inch) and heat-treated tempers. LSPT’s modeling capability guides the laser peen forming process to achieve specific part geometries within each variation of material. Validation of the modeling efforts have been completed via physical measurement of post-processed samples, and exhibit physical results that nominally agree with modeling predictions within a 5% accuracy.
Another benefit of laser peen forming lies in the selective application of this method to distorted components. The laser peening process can reshape and return non-conforming components to acceptable geometric tolerance bands, without bulk plastic deformation that may otherwise damage the structure. Due to the precision modeling and application capabilities of laser peen forming, it has been used to mitigate distortions in engine crankshafts with eccentric lobes.
Maximum deformation depends on material thickness. Forming is adjustable up to the maximum deformation by controlling power density, pulse width, and layers.
Additional constraint can preferentially mitigate or enhance deformation.
The technology can be applied to aviation, maritime (including repairs), and other industries where precise metal shaping is required. LSP Technologies models different modes of laser peen forming and uses a variety of laser peening parameters to achieve the desired shape.
Finite Element Analysis (FEA) simulates the imparted plastic strain along with the elastic response of the surrounding material. This allows accurate, scalable predictions.
Laser peen forming has numerous applications for fabrication and repair of parts with complex curves.
Laser peen straightening is a service life extension treatment that mitigates component distortion while improving fatigue strength of the part.
In both processes, LSP Technologies’ successful modeling and application of controlled plastic strain improves both geometric tolerances and residual stress profiles for enhanced reliability and performance.
Are you interested in learning more on how Laser Peen Forming works and the benefits you’ll see for your components? Talk with us to discover how Laser Peen Forming can add efficiency and precision for your applications.
