Macro-scale Residual Stresses Research Articles

Optimisation of process-induced residual stresses in composite laminates by different genetic algorithm and finite element simulation coupling methods

To address the residual stress induced during the cure of fibre reinforced thermoset polymer composites, two different approaches were suggested for coupling a non-dominated sorting genetic algorithm (NSGA-II) with finite element (FE) simulations based on a viscoelastic constitutive law. These two approaches were proposed with consideration of different ways of integrating NSGA-II and the FE model. In Approach A, NSGA-II was performed based on results from a series of simulations under various combinations of cure variables. Alternatively, Approach B employed NSGA-II to iteratively update and optimise the cure profile for subsequent simulations. Results indicated that both approaches achieved simultaneous reductions in cure time and macroscale residual stress, with Approach B showing further improvements due to the direct coupling between the NSGA-II and simulations. Specifically, the maximum residual stress and cure time optimised by Approach A were reduced by 5%–9% and 22%–50% respectively, while those obtained by Approach B were reduced by 7%–10% and 32%–49% respectively, compared to those based on the manufacturer recommended cure profile. The evolution of stress in composites based on optimised cure profiles from these two approaches was also elucidated. Additionally, microscale modelling further revealed a 3%–5% reduction in the average residual stress within a representative volume element (RVE) model was also shown, depending upon the approach adopted. Ultimately, by combining a NSGA-II and FE simulations, the optimisation of cure time and residual stress at the macroscale and cure time together with a reduction of microscale stress could be realised.

Multiscale residual stress and mechanical behavior analysis in machining of Ti-6Al-4V alloy with advanced microscopic characterization

Machining of polycrystalline metal materials results in metallurgical modifications in the machined surface, and it can introduce multiscale residual stresses (macroscale and microscale residual stress), which may be detrimental to the mechanical properties thereby interfering with the service performance of machined parts. However, most of the current studies only focus on the macroscale residual stress, the microscale residual stresses have always been neglected since the limitations of the commonly used techniques for residual stress measurement in machined surfaces. In this study, the recently developed Focused Ion Beam-digital image correlation (FIB-DIC) ring core method was employed to evaluate the time-resolved strain relaxation and multiscale residual stress of the machined surface under different cutting conditions. The quantitative evaluation of residual stress and microstructural effects on hardness of the machined surface was conducted by combining with FIB incremental milling and nanoindentation technique. It has been observed that although the global tensile strain relaxation was captured in the ring-core region, local microscale compressive strain relaxation also occurred. The hardness of the machined surface was determined by the combined effects of microstructure and residual stress induced by machining. Specifically, the grain refinement and compressive residual stress contributed to hardening, while tensile residual stress resulted in softening of the machined surface. Furthermore, it was also observed the hardening/softening effects were enhanced with increasing intensity of tension and compression.

Additively manufactured Haynes-282 monoliths containing thin wall struts of varying thicknesses

Magnitude and distribution of residual stresses in additively manufactured Ni-based superalloys may impact the mechanical performance of as-fabricated parts. Though electron beam powder bed fusion (E-PBF) can produce components with minimal defects and residual stresses compared to laser powder bed fusion and directed energy deposition, variations of them may occur within the complex geometry of a component, due to inherent variations of thermal signatures and the evolution of section modulus along the build direction. This work reveals the residual stress distribution, characterised from neutron diffraction, of an as-fabricated Haynes 282 monolith containing internal cube voids and thin wall struts of varying thicknesses. Complementary local hardness measurements and multi-scale microscopy were used to investigate the geometry-structure-property relationships. Observed variations in hardness were attributed to a combination of type I macro-scale residual stresses and variations in bimodal γ′ precipitation behaviour. The results highlight the influence of residual stresses and microstructure on the mechanical properties of E-PBF Haynes 282.

FIB-DIC Residual Stress Evaluation in Shot Peened VT6 Alloy Validated by X-ray Diffraction and Laser Speckle Interferometry.

Ga-ion micro-ring-core FIB-DIC evaluation of residual stresses in shot peened VT6 (Ti-6Al-4V) alloy was carried out and cross-validated against other non-destructive and semi-destructive residual stresses evaluation techniques, namely, the conventional X-ray diffraction and mechanical hole drilling. The Korsunsky FIB-DIC method of Ga-ion beam micro-ring-core milling within FIB-SEM with Digital Image Correlation (DIC) deformation analysis delivered spatial resolution down to a few micrometers, while the mechanical drilling of circular holes of ~2 mm diameter with laser speckle interferometry monitoring of strains gave a rough spatial resolution of a few millimeters. Good agreement was also found with the X-ray diffraction estimates of residual stress variation profiles as a function of depth. These results demonstrate that FIB-DIC provides rich information down to the micron scale, it also allows reliable estimation of macro-scale residual stresses.

A novel pathway for multiscale high-resolution time-resolved residual stress evaluation of laser-welded Eurofer97.

The plasma-facing components of future fusion reactors, where the Eurofer97 is the primary structural material, will be assembled by laser-welding techniques. The heterogeneous residual stress induced by welding can interact with the microstructure, resulting in a degradation of mechanical properties and a reduction in joint lifetime. Here, a Xe+ plasma focused ion beam with digital image correlation (PFIB-DIC) and nanoindentation is used to reveal the mechanistic connection between residual stress, microstructure, and microhardness. This study is the first to use the PFIB-DIC to evaluate the time-resolved multiscale residual stress at a length scale of tens of micrometers for laser-welded Eurofer97. A nonequilibrium microscale residual stress is observed, which contributes to the macroscale residual stress. The microhardness is similar for the fusion zone and heat-affected zone (HAZ), although the HAZ exhibits around ~30% tensile residual stress softening. The results provide insight into maintaining structural integrity for this critical engineering challenge.

Controlling melt pool shape, microstructure and residual stress in additively manufactured metals using modified laser beam profiles

Laser powder bed fusion has proven to be an effective additive manufacturing technology for the manufacture of complex metal components. However, the local thermal history associated with Gaussian beam, raster scan processes produces heterogeneous and spatially non-uniform microstructures that differ from those produced from conventional manufacturing and often lack optimized mechanical properties. Steep thermal gradients and high cooling rates produce large thermal strains driving residual stress fields that can negatively affect the dimensional accuracy of the as-built component. Here, we present experimental and simulation methods for controlling microstructure and residual stress through tailored laser beam profiles. Elliptical and Bessel beam profiles are shown to produce more equiaxed microstructures as compared to those of Gaussian beams, while distributed diode-based illumination profiles allow for reduced residual stresses. These experimental results are supported by high-fidelity powder-scale simulation models coupled to the cellular automata and thermomechanical models that account for macroscale residual stress.

Directional and oscillating residual stress on the mesoscale in additively manufactured Ti-6Al-4V

In additive manufacturing of metals as compared to conventional processing, the directional track-by-track and layer-by-layer nature of the fabrication process can lead to residual stresses that locally are both directionally and spatially heterogeneous. Much of the existing literature has focused either on the macroscale residual stress inside the entire part, or on the microscale residual stresses that are created around a scan vector, thereby neglecting the intermediate length-scale of the different layers. The objective of this research is to investigate such mesoscale residual stress distributions across several layers in Ti-6Al-4V components produced by laser metal deposition process. The incremental centre hole drilling and incremental slitting methods provide measurements with excellent spatial resolution within and across the layer length scale. In this work, the two methods complemented each other to quantify both mesoscale and directional variations of residual stress that correlate with the deposition pattern. Our findings also provide strong evidence that an oscillatory residual stress variation persists even after thermal cycling that occurs during deposition of subsequent layers.

Effect of processing parameters on the densification, microstructure and crystallographic texture during the laser powder bed fusion of pure tungsten

Laser Powder Bed Fusion is a leading additive manufacturing technology, which has been used successfully with a range of lower melting point materials (titanium alloys, nickel alloys, steels). This work looks to extend its use to refractory metals, such as those considered in this paper where the behaviour of pure tungsten powder is investigated. A strategy for fabricating high density parts was developed by creating a process map in which the effect of laser energy density was studied. The process quality was assessed using different techniques including light optical microscopy, XCT, SEM and EBSD. The results showed that the laser energy density was adequate to process tungsten to produce functional parts. The bulk density and optically determined densities, under different process conditions, ranged from 94 to 98%, but there was evidence of micro cracks and defects in specimens due to micro- and macro-scale residual stress. Analysis of the microstructure and local crystallographic texture showed that the melt pool formed under the laser beam favoured solidification in a preferred orientation by an epitaxial growth mechanism. The EBSD local texture analysis of the tungsten specimens showed a <111>//Z preferential fibre texture, parallel to the build direction.

Experimental study of the effects of wire EDM on the characteristics of ferritic steel, at a micro-scale on the contour cut surface

This study, on a micro-scale, of the WEDM cut surfaces of specimens to which the contour method of residual stress measurement is being applied provides detailed information about the effects of the cutting process on the surface quality. This is defined by a combination of several parameters: variation in surface contour profile, sub-surface damage and surface texture. Measurements were taken at the start, the middle and at the end of the cut. This study shows that during WEDM cutting, a thin layer, extending to a depth of a few micrometres below the surface of the cut, is transformed. This layer is known as the recast layer. Using controlled-depth etching and X-ray diffraction, it is shown that this induces an additional tensile residual stress, parallel to the plane of the cut surface. The WEDM cut surface and sub-surface characteristics are also shown to vary along the length of the cut. Moreover, these micro-scale changes were compared with macro-scale residual stress results and provides an indication of the point at which the changes occurred by cutting process can be significantly relative to the macro-scale residual stress in a specimen.

Stress generation during the quenching of large AA2618 forgings: Finite element computations and validation against neutron diffraction measurements

Solutionising and quenching are key steps in the fabrication of heat treatable aluminium parts such as AA2618 compressor impellers for turbochargers. Quenching not only dictates the mechanical characteristics of the product but also induces residual stresses that can cause unacceptable distortions during machining and unfavourable stresses in service. Predicting and controlling stress generation during quenching of large AA2618 forgings is therefore of great interest. Since possible precipitation during quenching may affect the local yield strength of the material and thus impact the level of macro-scale residual stresses, consideration of this phenomenon is required.A phenomenological material model accounting for precipitation in a simple way is used instead of modelling in detail precipitation that occurs during quenching. The required model parameters are identified using a limited number of tensile tests achieved after representative interrupted cooling paths in a Gleeble machine. This model is used in FE computations of stress generation during quenching of large massive AA2618 forgings for compressor impellers. The residual strain and stress profiles are compared with neutron diffraction measurements carried out at SALSA and STRESS-SPEC diffractometers in as-quenched and in T6 conditions. It turned out that the residual stress predictions by FE modelling might be wrong if precipitation is not taken into account properly in the material model.

Relationship between indentation plastic zone size and residual stresses in plastically deformed Fe

Indentation induced plastic zone size was studied using electron channelling contrast imaging in polycrystalline Fe. Nanoindentation tests were carried out in samples that were compressed to different degrees of thickness reduction. Both strain hardening and residual stresses induced by the compression contributed to significant hardness elevations at all levels of thickness reduction. By comparing between the un-deformed and pre-deformed samples, texture and strain hardening effect were found to contribute to the differences between stresses at micro and macro scales. A correction for texture effects applied to average micro-stresses brought their values close to the macro-stresses. For each sample, a linear relationship was found between the cube of the plastic zone size measured and the inverse of the hardness. The slope of the linear trend line was shown to increase with increased compressive macro-stress level as determined by X-ray diffraction (XRD). This newly discovered empirical relationship demonstrated the potential of predicting macro-scale residual stress levels from nanoindentation experiments.

Measurement of microscale residual stresses in multi-phase ceramic composites using Raman spectroscopy

A methodology is described for characterizing the spatial distribution of thermal mismatch stresses at grain level in B4C-SiC-Si ceramic composites using Raman spectroscopy. Unlike traditional methods to detect residual stresses (e.g., X-ray diffraction) which provide average values of stress over the entire specimen surface, Raman peak-shift analysis provides residual stress distributions within the microstructure at high spatial resolution. While classical formulation predicts uniform compressive stress within a Si-phase surrounded by the ceramic matrix, the Raman measurements revealed non-uniform residual stress distributions in Si when the particle size was larger than 5 microns. For large irregular shaped particles, the two methods coincide only along the interface between the particle and matrix, but vary drastically both in magnitude and nature in the interior of the particle where large tensile stresses have been measured. The presence of anomalous tensile stress in the interior of the minor Si-phase results in defect generation and structural disorder which has been confirmed by TEM analysis. Raman spectroscopic mapping was also used to compute an average macroscale residual stress value for a given material composition allowing links to be drawn between processing, microstructure and properties. The average residual stress within the microstructure was found to correlate well with the estimates based on volume fraction of the constituents and material properties.

Applying electron backscattering diffraction to macroscopic residual stress characterisation in a dissimilar weld

Dissimilar metal welds are complicated in nature because of the complex microstructure characteristics in the weld fusion zone. It is often necessary to know the phase distribution in a dissimilar metal weld especially at the interface such as fusion zone and heat affected zone to be able to predict the behaviour of the joint and its fitness for service. In this paper, a dissimilar metal weld made between ferritic/martensitic modified 9Cr-1Mo steel (P91) and austenitic AISI 316LN stainless steel using autogenous electron beam (EB) welding was analysed. The weld fusion zone has a local segregation of bcc and fcc phases. The EBSD technique was applied to determine the volume fractions of each of these phases in the weld fusion zone. This information was incorporated into the analysis of neutron diffraction data from the weld zone, and the macro-scale residual stresses were calculated from phase-specific stresses arising from the welding process. The results indicate that the overall macroscopic residual stress distribution in the weld centre is predominantly compressive in nature driven by the solid-state phase transformation of the weld pool during rapid cooling, with tensile peaks pushed adjacent to the heat affected zone (HAZ)/Parent boundaries on both sides of the fusion zone.

Measurements and Modeling of Stress in Precipitation-Hardened Aluminum Alloy AA2618 during Gleeble Interrupted Quenching and Constrained Cooling

Solutionizing and quenching are the key steps in the fabrication of heat-treatable aluminum parts such as AA2618 compressor impellers for turbochargers as they highly impact the mechanical characteristics of the product. In particular, quenching induces residual stresses that can cause unacceptable distortions during machining and unfavorable stresses in service. Predicting and controlling stress generation during quenching of large AA2618 forgings are therefore of particular interest. Since possible precipitation during quenching may affect the local yield strength of the material and thus impact the level of macroscale residual stresses, consideration of this phenomenon is required. A material model accounting for precipitation in a simple but realistic way is presented. Instead of modeling precipitation that occurs during quenching, the model parameters are identified using a limited number of tensile tests achieved after representative interrupted cooling paths in a Gleeble machine. This material model is presented, calibrated, and validated against constrained coolings in a Gleeble blocked-jaws configuration. Applications of this model are FE computations of stress generation during quenching of large AA2618 forgings for compressor impellers.

Novel implementations of relaxation methods for measuring residual stresses at the micron scale

The advent of dual-beam focused ion beam - field emission gun scanning electron microscope (FIB-SEM) imaging and milling systems in combination with digital image correlation (DIC) analysis has made it possible to make very fine excisions and to record the resulting displacements with nanometre precision. This has led to novel implementations of macroscale residual stress measurement methods to the microscale, for example, micro-slotting, micro-hole drilling and so on. This review article outlines the different methods for residual stress mapping at the micron scale highlighting their relative merits and limitations with the aim of guiding the user towards the most appropriate techniques for a given application. These open new possibilities for residual stress measurement not just at the continuum scale but even for mapping stresses within grains. In addition, recent advances in milling throughput promised by new dual-beam plasma focused ion beam systems promise to help bridge the gap between the conventional macroscale methods and their micron-scale counterparts.

Quench-Induced Stresses in AA2618 Forgings for Impellers: A Multiphysics and Multiscale Problem

In the fabrication of heat-treatable aluminum parts such as AA2618 compressor impellers for turbochargers, solutionizing and quenching are key steps to obtain the required mechanical characteristics. Fast quenching is necessary to avoid coarse precipitation as it reduces the mechanical properties obtained after heat treatment. However, fast quenching induces residual stresses that can cause unacceptable distortions during machining. Furthermore, the remaining residual stresses after final machining can lead to unfavorable stresses in service. Predicting and controlling internal stresses during the whole processing from heat treatment to final machining is therefore of particular interest to prevent negative impacts of residual stresses. This problem is multiphysics because processes such as heat transfer during quenching, precipitation phenomena, thermally induced deformations, and stress generation are interacting and need to be taken into account. The problem is also multiscale as precipitates of nanosize form during quenching at locations where the cooling rate is too low. This precipitation affects the local yield strength of the material and thus impacts the level of macroscale residual stresses. A thermomechanical model accounting for precipitation in a simple but realistic way is presented. Instead of modelling precipitation that occurs during quenching, the model parameters are identified using a limited number of tensile tests achieved after representative interrupted cooling paths in a Gleeble machine. The simulation results are compared with as-quenched residual stresses in a forging measured by neutron diffraction.

An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel

Additive manufacturing (AM) technology provides unique opportunities for producing net-shape geometries at the macroscale through microscale processing. This level of control presents inherent trade-offs necessitating the establishment of quality controls aimed at minimizing undesirable properties, such as porosity and residual stresses. Here, we perform a parametric study into the effects of laser scanning pattern, power, speed, and build direction in powder bed fusion AM on residual stress. In an effort to better understand the factors influencing macroscale residual stresses, a destructive surface residual stress measurement technique (digital image correlation in conjunction with build plate removal and sectioning) has been coupled with a nondestructive volumetric evaluation method (i.e., neutron diffraction). Good agreement between the two measurement techniques is observed. Furthermore, a reduction in residual stress is obtained by decreasing scan island size, increasing island to wall rotation to 45 deg, and increasing applied energy per unit length (laser power/speed). Neutron diffraction measurements reveal that, while in-plane residual stresses are affected by scan island rotation, axial residual stresses are unchanged. We attribute this in-plane behavior to misalignment between the greatest thermal stresses (scan direction) and largest part dimension.

Analysing thermally induced macro-scale residual stresses in tailored morphing composite laminates

An approach for predicting and extracting through-thickness residual stresses in tailored composite laminates (i.e. laminates with local variations in lay-up sequence and/or thickness) is presented. Tailored composite laminate configurations can be explored in some novel structural applications (e.g. morphing laminates) by incorporating unsymmetric laminate lay-up sequences. In such cases, the presence of and variation in through-thickness (i.e. macro-scale) residual stresses can considerably influence the structural geometry, strength and multi-stable behaviour of these laminates, and thus require consideration at a design stage. In this context, a combined numerical-experimental approach was used to analyse residual stresses in tailored laminates. Laminates with local unsymmetric cross-ply lay-ups and/or varying thicknesses were manufactured at elevated temperatures and experimental measurements (of cured shapes at room temperature) were used to develop laminate-level finite element models. The cured laminate shapes were measured using a full-field non-contact technique. The numerical models were calibrated and subsequently used to extract through-thickness residual stresses in the laminates. It was shown that the current approach can be successfully applied to predict the cured shapes of and the through-thickness residual stresses in tailored laminates.

Residual stress distribution in spray atomized and deposited Ni 3Al

Spray atomization and deposition involves disintegrating a molten stream of metal into micrometer-sized droplets with a high velocity gas, and subsequently deposition the mixture of solid, liquid, and partially solidified droplets on a substrate surface. This synthesis methodology has attracted considerable attention as a viable processing alternative for structural materials, and has been successfully applied to numerous alloy systems. Residual stresses are almost always present during processing, often due to the presence of thermal or other gradients. It is well established that significant amounts of residual stresses develop during conventional casting, and heat treatments, etc. The presence of compressive residual stresses in the surface layer of a component, for example, can dramatically improve the mechanical properties of a material, such as fatigue life and corrosion resistance. In most cases, however, the presence of residual stresses deteriorates the mechanical properties of the material, often leading to distortion of the component or even to the formation of cracks. The objective of the present study was to measure the distribution of macro-scale residual stresses in materials processed by spray atomization and deposition, and to investigate the relationship between the residual stresses and the processing conditions. Accordingly, X-ray diffraction analysis was utilized to measuremore » the residual stresses of a spray deposited Ni[sub 3]Al, and the results were elucidated in terms of the thermal extraction mechanisms that are present during spray atomization and deposition.« less