Under cyclic loading, aluminum alloys exhibit less fatigue life than steel alloys of similar strength and this is considered as Achilles's heel of such alloys. A nanosecond fiber laser was used to apply high speed laser shock peening process on thin aluminum plates in order to enhance the fatigue life by introducing compressive residual stresses. The effect of three working parameters namely the pulse repetition rate (PRR), spot size (ω) and scanning speed (v) on limiting the fatigue failure was investigated. The optimum results, represented by the longer fatigue life, were at PRR of 22.5 kHz, ω of 0.04 mm and at both v's of 200 and 500 mm/sec. The research yielded significant results represented by a maximum percentage increase in the fatigue life of 505.25% accompanied by the least deformation for the processed surfaces. SEM images for the specimens processed by the optimum process conditions imply no ablation has occurred at the surface, and the process is completely cold. X-ray diffraction analysis indicates a reduction in grains size, an increase of 28.56% in the lengths of dislocations and formation of effective compressive residual stress at the surface and beneath reaches to 700 μm.
