The Influence of Deep Rolling on the Surface Integrity of Annealed Aisi 1045 Steel

Deep rolling is a mechanical surface treatment primarily applied to improve surface finish and fatigue strength of metallic components by inducing plastic deformation in the surface layer. Recently, it has also been explored as an alternative to enhance corrosion resistance. This study evaluates how deep rolling parameters affect surface integrity of annealed AISI 1045 steel. Deep rolling significantly reduced surface roughness, especially at the highest pressure (14 MPa). Despite this, electrochemical tests showed no improvement in corrosion resistance. However, fatigue tests revealed that deep rolling notably increased fatigue life after corrosion exposure. The best performance occurred with the highest pressure and lowest feed rate (14 MPa and 0.04 mm/rev), where fatigue life surpassed even the as-turned, non-corroded condition. Microstructural analysis confirmed localized subsurface deformation after deep rolling, followed by microhardness measurements that revealed an increase in hardness in the near-surface region, indicating strain hardening. Fractography showed fewer ratchet marks in deep-rolled specimens compared to as-turned ones after corrosion.