ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
(OP)
Our company is producing a 6061 aluminum extrusion product which has a number of holes that require roller burnishing.
The process itself has been successful, but I am looking for input on service temp limits of the part after the burnishing has been completed. I ask the question because we have seen a spec from an OEM which limits temperature on a similar item to 250F. Does anyony have information on how or why this specific temp was chosen?
Details are: Hole size -.4375
Expansion - .0004-.0008
Surface finish - 16 Ra maximum
Any thoughts are appreciated.
The process itself has been successful, but I am looking for input on service temp limits of the part after the burnishing has been completed. I ask the question because we have seen a spec from an OEM which limits temperature on a similar item to 250F. Does anyony have information on how or why this specific temp was chosen?
Details are: Hole size -.4375
Expansion - .0004-.0008
Surface finish - 16 Ra maximum
Any thoughts are appreciated.





RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
Creep may be an issue with 6061 above 250F for sustained loading conditions. Check MIL-HDBK-5 for more information.
Regards,
Terry
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
Just to clarify, the final use of this part will NOT see a continuous 250F. During final assy it experiences the temps for a breif time(60 min) during an adhesive cure. Some concern has been raised wheteher this degree/time frame would do harm to the roller burnish or decrease its effectiveness.
Thanks again.
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
That compressive residual stress induced by the roller burnishing, and which provides a degree of protection against fatigue crack growth, will decay (stress relaxation) with exposure to high temperatures, due to the same mechanisms that allow the allow the material to creep as tbuelna pointed out.
Yes, in a perfect world, the part would ideally be roller burnished after all paint/adhesive cure is complete...but that may not be possible.
Has the part exhibited fatigue cracking in field service?
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
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RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
The the early version of this part was not roller burnished, but the OEM started to incoporates it later in production. It is a life limited part, so we assume the process was added to enhance as such. We have an STC/PMA to re-create the part and wanted to be making the best version.
You are correct in that we cannot roller burnsh afer final bonding due to tooing and part configuration. I am hoping to get some "tribal knowledge" on the 250F being a hard limit or not.
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
You say "about 250"?
If we got some confirmation on a 250-260 range there would be no worries.
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
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RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES
The whole paper is not in German, see page 147 and on for the section of most interest for you (all in English).
Also see equations #2 and #3 (page 12, again in English) for the theoretical equations for the decay of residual stress vs. time and temperature. You'll find that the problem is defining an "acceptable" level of decay of the residual stress, or an acceptable level of diminished fatigue life.
RE: ALUMINUM ROLLER BURNISH SERVICE TEMPERATURES