Does someone have a table that has the minimum shot size for a given intensity in a perfect world (without concern for fillets or shielded areas), and the absolute minimum shot size.

If you go to our web site and "learning on-line" you can retrieve the military spec on shotpeening, MIL-S-13165. This has a table of shot sizes to be used for peening. Click on http://www.shotpeener.com/learning/spec.htm to access the specs.

Although I may have missed it, I didn't see something like:
for an intesity of 8 to 12A, a shot size of SXXX or larger must be used with the perferable size of SYYY or larger

See section 3.3.8

3.3.8 Minimum Shot Size for Peening Materials. Except as otherwise specified or permitted, or in cases such as when shielded areas are involved, materials shall not be peened with shot smaller than the following for the intensities given:
Intensity Peening Media
.012A S-280 or CW-28 or GB (.039-.028) or ceramic bead size .033

.016A S-390 or CW-41 or GB (.056-.039) or ceramic bead size .046

.020A S-550 or CW-54 or GB (.079-.056)

[This message has been edited by jChampaigne (edited February 20, 2004).]