Presence Of Residual Stresses Research Articles

Residual Fatigue Life Estimation of Damaged Welded Structures

This paper presents a finite element modeling procedure to determine of crack growth behaviour of butt welded joints under the subject of load for mode I. This paper presents a computation procedure to determine the ratio of fatigue crack growth in butt welded plates for mode I fracture mechanics loading conditions. The presence of residual stresses in welded structures can significantly affect the material’s resistance to fatigue under cyclic loading. The presence of tensile residual stresses adversely affects the fatigue crack growth rate increased it. Change of microstructure and hardening material as a result of the welding process also has a negative impact on the growth of the crack. Accurate prediction and reliable assessment of the residual stress are important for the structural integrity and residual life assessment of welded parts design. Although there are several techniques for the determination of residual stresses, the finite element method (FEM) is one of the most convenient and useful. This paper presents a finite element modeling procedure to determine of crack growth behaviour of butt welded joints under tensile load for mode I. Keywords: Welding, Residual stress, Residual life, Crack growth, FEM, Butt welded joint

Residual stress induced granular bright facets around inclusions in high-strength steels under high-cycle fatigue

Granular bright facets (GBFs) are frequently observed adjacent to inclusions and within fish-eye areas in the fatigue fractures of high-strength steels under very-high-cycle fatigue (VHCF), considered as a characteristic fracture feature of VHCF. Previous understanding on GBF formation emphasizes the occurrence of nanocystallization in microstructure. In this study, however, the same morphology can also be observed under high-cycle fatigue (HCF). GBF, although closer to fatigue crack initiator and experiencing more stress cycles than the peripheral part of fish-eye (PPFE), exhibits rougher surface morphology in the absence of accumulated plastic strain in microstructure, manifesting relieved crack surface wear. This indicates that the traditional theories on GBF formation for VHCF becomes invalid for HCF. The root cause for GBF formation under HCF is analyzed to be the presence of residual stress around inclusions, which reduces the contact pressure of fatigue crack surfaces inducing wear relief. Accordingly, an analytical model capable of predicting GBF thickness with the effects of HCF conditions and steel properties taken into consideration is established. The model yields accurate predictions of GBF thickness with various loading stresses and inclusion diameters, validated by experimental observations. This study provides theoretical guidance for HCF fracture analysis and fatigue life prediction.

Relaxation of residual stress in welded plates during long life fatigue loading

The presence of residual stress in welded components can have a significant impact on fatigue response. Residual stresses were assessed in thick welded A36 cantilever specimens (T-specimens) at the fatigue critical area. Testing involved subjecting the T-specimens to varying bending stresses and load cycles, leading to different levels of local plasticity at the weldtoe. Extensive X-ray diffraction (XRD) measurements were conducted to analyze the residual stress distribution near the weldtoe. Residual stress states were evaluated in both as-welded specimens and those subjected to fatigue loading with strain amplitudes up to 0.001 at the weldtoe stress concentration zone. The findings suggest that fatigue loading can induce changes in the welding-induced residual stress field, ranging from moderate to significant alterations. Therefore, fatigue life predictions should consider the potential evolution of residual stresses due to cyclic loading, including the effects of cyclic stress relaxation in fatigue life calculations.

Effect of Boron on Stress Corrosion Resistance of S31254 Super‐Austenitic Stainless Steel After Cold Deformation

The effect of boron (B) on stress corrosion resistance of S31254 in the presence of residual stresses has been studied. The microstructure and corrosion resistance of S31254 containing B at different levels of cold deformation are analyzed in this study. In the results, it is shown that B favors the improvement of deformation uniformity of S31254. The grain boundary (GB) and slip bands have better corrosion resistance at 5% deformation, and the overall corrosion resistance is better than that of the undeformed state, with smaller passivation current density and narrower width of GB corrosion grooves, especially for the 40B samples. At 30% deformation, the overall corrosion resistance of 40B S31254 is better than 0B due to improved deformation uniformity.

Investigation of the Influence of NiBSi/NiCrBSi Coatings Applied by Flame Spraying with Simultaneous Fusing on the Substrate Material

The aim of this research is to investigate the influence of nickel alloy type from the same group, the parameters of flame spraying, as well as the preparation of the substrate and the heat treatments of the substrate on the microstructure of the coating/substrate system. Due to the possibility of applying nickel alloys in corrective maintenance of tools used on elevated working temperatures, hot work tool steel X38CrMoV5-1 was selected as a substrate material. The investigation of the microstructure of the coating/substrate system was carried out according to the factorial design of experiment, where the input factors were varied on two levels. The factors that were varied are: Ni based self-fluxing alloys - NiCrBSi and NiBSi; distance of the burner from the workpiece - small (6 mm) and large (20 mm); preparation of the substrate - roughened and non roughened and the heat treatments of the substrate - soft annealed and tempered condition. Ni-based self-fluxing alloys were applied on samples (12,5 × 25 × 25 mm) by flame spraying with simultaneous fusing process. Analysis of the microstructures of the coating/substrate system was carried out on the Leica DM 2500M light microscope. After the conducted analysis the paper concluded that by spraying the selected coatings onto the X38CrMoV5-1 tool steel base, poor quality coatings are obtained, due to the appearance of cracks (NiCrBSi) or separation of the coating from the substrate (NiBSi). This is attributed to the formation of martensitic structure of the substrate after spraying and the presence of residual stresses.

Numerical simulations of residual stress formation and its effect on fatigue crack propagation in a fillet welded T-joint

The welding process induces residual stresses because of the non-uniform heating and cooling of the material. Residual stresses are known to influence fatigue crack growth. However, studies addressing both the formation of residual stress – giving a realistic multi-directional stress and strain field – and redistribution of residual stresses due to crack growth in the case of a surface crack have not been found. The extended finite element method was employed in this study to evaluate the stress intensity factors of a planar, growing crack in a welded T-joint with and without welding induced residual stresses. The initial residual stress field was taken from a welding simulation using the finite element method. The redistribution of the residual stress field due to crack growth was studied in addition to the shape and growth rate of the planar crack. The study shows that, in agreement with experimental evidence, the external stress ratio has a significant influence in the absence of residual stress but it does not have a significant influence in the presence of residual stress. The current study gives insight into the cause of this observation.

Measurement of laser shock peening induced residual stress by nanoindentation and comparison with XRD technique

Laser shock peening (LSP) is an innovative surface treatment technique successfully used to improve fatigue performance of metallic components. It is based on the application of high intensity laser and suitable overlays with the aim to generate high pressure shock waves on the surface of the mechanical part to be treated. Shock waves generate severe plastic deformations and, consequently, compressive residual stresses (RS). An accurate measurement of these latter is crucial for predicting the resistance of treated parts under service loads and to assess the effectiveness of LSP process.In this paper, a non-destructive method, based on the nanoindentation technique and finite element analysis (FEA), was developed to measure the RS generated by LSP process on AA-7050-T451 samples. In particular, the methodology is based on the analysis of the nanoindentation peak load variation generated by the presence of residual stresses on a component. Obtained results were compared, for validation, with the measurements carried out by the most consolidated X-ray diffractometer (XRD) technique. The results showed a satisfactory agreement between the two techniques, revealing nanoindentation as a promising and reliable method for characterizing RS induced by LSP.

Application of Installations with Uniform-Strength Beams as Working Deformation Standards

A method for obtaining homogeneous deformation along the length of the measuring section of a uniform-strength beam and the possibility of its application as part of a working deformation standard are considered. The results of the analysis of the bending model and the design of a uniform-strength beam are presented. In the focus of attention are the parameters included in the measurement equation and related to methodological factors, as well as influencing the result of relative deformation measurements. The subjects of research are the presence of contact friction forces, heterogeneity of material properties, the special nature of the load application (bending, torsion, the presence of residual stresses in the body, geometrical parameters of the calibration beam, orientation of primary transducers on the beam, application of bending load, measurement of deflection and displacement of the neutral layer). The advantages and disadvantages of using a uniform-strength beam for determining the characteristics of primary strain transducers during testing, calibration, and verification were established. The deviation of signals of primary transducers located outside the axial cross-section when oriented along the beam axis and along the force lines converging at the point of load application was experimentally revealed. The error due to the orientation of the primary transducers on the beam depending on the angle between the lateral faces can range from 0.15 to 0.23 %. The study adds to the theoretical knowledge base on the possibility of using a cantilever uniform-strength beam as a load-bearing element in calibration installations. The conclusions may be useful for testing, calibrating, and verifying primary strain transducers.

Response of surface effect on plane wave reflection at the boundary of flexomagnetic substrate

The article delves into the reflection of bulk plane waves in a flexomagnetic slab with second-order gradient elasticity. Employing generalized Gurtin-Murdoch surface elasticity, the study provides analytical insights into amplitude ratios and energy flux ratios for reflected bulk waves. The investigation focuses on understanding the behavior and energy conversion of incident bulk waves in the reflected P-SV system, highlighting the influences of residual surface stress, surface elasticity, and flexomagnetic polarization. The outcomes of the study indicate the high amplitude in the presence of residual stress. The findings contribute to fundamental knowledge for nanoscale piezomagnetic structures and potential applications in magnetic acoustic wave devices.

The application of the X-ray diffraction method in the assessment of PT bridges

The present research focuses on the application of the X-ray diffraction method as a non-destructive testing technique to evaluate the stress level in tendons of post-tensioned (PT) elements, such as the ones characterizing large-span infrastructures. The knowledge of the stress level can provide relevant information about the maintenance condition of PT structures, highlighting the possible presence of criticisms. The X-ray methodology investigates the stress state on the near-surface region of the element: the resulting measure is therefore strongly influenced by the presence of residual stresses, that need to be somehow estimated. Residual stresses are induced by the manufacturing process: wires and strands are produced by applying a cold-drawing process to high-strength steels; the thermo-mechanical treatment is realized by imposing continuous heating on tensioned specimens. This latter process reduces the relaxation of cables and relieves the residual stresses induced by the drawing, that are, however, generated. The present work aims to determine the main factors affecting the measures, with a particular focus on residual stresses.

Tensile/Compressive Response of 316L Stainless Steel Fabricated by Additive Manufacturing

Additive manufacturing has evolved from a rapid prototyping technology to a technology with the ability to produce highly complex parts with superior mechanical properties than those obtained conventionally. The processing of metallic powders by means of a laser makes it possible to process any type of alloy and even metal matrix composites. The present work analyzes the tensile and compressive response of 316L stainless steel processed by laser-based powder bed fusion. The resulting microstructure was evaluated by optical microscopy. Regarding the mechanical properties, the yield strength, ultimate tensile strength, percentage of elongation before breakage, compressive strength and microhardness were determined. The results show that the microstructure is constituted by stacked micro molten pools, within which cellular sub-grains are formed due to the high thermal gradient and solidification rate. The compressive strength (1511.88 ± 9.22 MPa) is higher than the tensile strength (634.80 ± 11.62 MPa). This difference is mainly associated with strain hardening and the presence of residual stresses. The initial microhardness was 206.24 ± 11.96 HV; after the compression test, the hardness increased by 23%.

A Novel Method for Predicting Residual Stress in GH4169 Machined Surfaces through Micro-Hardness Measurement

The presence of residual stress seriously affects the mechanical performance and reliability of engineering components. Here, the authors propose a novel method to determine corresponding residual stress through micro-hardness measurements of machined surfaces. In this study, a mathematical model with equal biaxial stress indentation is established. Then, the correlation of micro-hardness with indentation and residual stress is used to determine the prediction equation of residual stress. The material applied in this study is the nickel-based Superalloy GH4169. The residual stress prediction formula for Superalloy GH4169 is ultimately determined through the finite element method by subjecting the indentation to residual stress and fitting the experimental test data. The relationship between the indentation modulus and indentation depth is given quantitatively. The relationship between residual stress and hardness is given quantitatively. The prediction results show that the compressive residual stress can enhance the material hardness and make the contact deformation only require a low indentation depth to achieve complete plastic deformation. Conversely, the tensile residual stress can result in a deeper depth and less hardness at the initial stage of the fully plastic state. For the materials that yield more easily (small ratio of elastic modulus to yield strength), the effect is more evident. The model presented in this paper can accurately forecast corresponding residual stress through measurements of the micro-hardness of machined surfaces.

Characterization and ion-irradiation studies of typical microstructures in nuclear graphite

Nuclear graphite is an important structural material for advanced gas cooled reactors and molten salt reactors. Graphite microstructures are always accompanied with typical pores or cracks which plays an important role in nuclear graphite behaviors. A new surface processing method involving ion milling and fast oxidation is used here to characterize typical microstructures from the large-size calcination cracks in fillers to very small quinoline insoluble particles in NBG-17 and NBG-18 graphites. By using this surface processing method and ion irradiation technique, an attempt is made to explore the microstructural basis of graphite irradiation behaviors. Heating-induced relaxation of graphite microstructures is observed, indicating the presence of residual stresses in nuclear graphite. Creased graphite sheets are identified on ion-milled surface and are believed to accommodate a-axis shrinkage of graphite crystallites at the beginning of irradiation, which is consistent with the initial plateau of slow dimensional shrinking. Compared to NBG-17 graphite, NBG-18 is found to have much more calcination cracks which contract during irradiation, resulting in a deeper volume shrinkage of NBG-18. The quinoline insoluble particles containing chaotic structures are shown to severely contract and separate from surrounding structures, leading to voids in between. Both NBG-18 and NBG-17 have abundant quinoline insoluble particles, which might make a contribution to their smaller volume shrinkage than other medium-grain graphite.

A Novel Method to Measure Equi-Biaxial Residual Stress by Nanoindentation

BackgroundThe accurate measurement of residual stresses (RS) is crucial for predicting the performance of mechanical components, as RS can significantly impact fatigue life, fracture, corrosion, and wear resistance. Different experimental methods were developed to measure RS, including non-destructive techniques. Among these methods, instrumented nanoindentation has emerged as a promising approach to assess equi- or non-equi-biaxial RS states. This technique analyzes variations in the mechanical response of indentation on a stressed or stress-free component to estimate residual stresses. Previous studies proposed different approaches to establish a relationship between RS and indentation parameters, such as contact area, peak load, mean contact pressure, indentation work, etc. However, the correlation between RS and peak load variation, commonly assumed to be linear, showed limitations, particularly when dealing with compressive RS.ObjectiveThe aim of this work is to develop a hybrid procedure, based on finite element (FEM) simulations and experimental analyses, to measure the equi-biaxial residual stresses. In particular, it is based on the analysis of the nanoindentation peak load variation generated by the presence of residual stresses on a component.MethodsTo overcome the limitations of the linear assumption, nanoindentation experiments were combined with finite element analyses (FEA). FEA simulations were used to estimate the correlation between RS and peak load variation, providing a better understanding of the non-linear relationship. A proper experimental setup, consisting in a stress generating jig, was designed and manufactured to perform nanoindentations on a sample, made by aluminium alloy AA 7050 T451, subjected to external mechanical stress with the aim to validate the FEA model. FEA and the digital image correlation (DIC) technique were also used to verify that the induced stress field was the expected one.ResultsObtained results revealed that the proposed method is a valid way to measure residual stresses. In fact, it offers an improved correlation between RS and peak load variation. In addition, by integrating nanoindentation experiments and FEA, a more accurate assessment of RS can be also achieved.ConclusionsThis research contributes to the development of a consistent methodology for RS measurement using instrumented nanoindentation.

Non-Linear Behavior and Design of Steel Structures: Review and Outlook

The high strength and stiffness-to-weight ratios of structural steel often result in relatively slender members and systems, which are governed to a great extent by stability limit states. However, predicting the stability of slender structures is difficult due to various inherent uncertainties in material and geometry. Generally, structural and member stabilities are nonlinear problems that cannot be directly evaluated based on the section strength using conventional analysis method. Nonlinear behaviors are basically categorized as materially and geometrically nonlinear, which can be observed at the cross-sectional, member, and frame levels. To provide a comprehensive understanding of the current state-of-the-art non-linear behavior and design of steel structures and to identify key areas for future research and development, this paper presents a review on the materially and geometrically nonlinear effects of steel structures. A discussion of the effects of material yielding accentuated by the presence of residual stresses, initial imperfections, and end conditions will be conducted. The stiffness reduction due to second-order effects and material yielding will be illustrated. Moreover, current and emerging design approaches that consider nonlinear responses will also be reviewed and evaluated. Lastly, with the development of modern flexible and complex steel structures, which sometimes violate fundamental assumptions of the current stability design method, the application of advanced analysis and design methods will be explored.

A Review on Residual Stress in Metal Additive Manufacturing.

A new method for producing parts in the expanding sector is additive manufacturing. The appropriate name for three-dimensional (3D) printing is additive manufacturing because it produces the part layer by layer. Plastics and metals can be 3D printed in large quantities with the precise surface finish and feature quality needed in additive manufacturing. More specifically, direct metal sintering, direct energy deposition, and metal binder jetting are used in 3D printing. The computer-aided design model is completed when the powder bed has been successively scanned and lowered. The metal sintering process uses a powder bed with powder metal, and laser selectively melts a flattened bed of powder, which is done with roller with successive rolling of new layer on previous into desired shape before a new layer is pushed on top of the previous layer. As a result, the new layer has solidified on top of the earlier layer, causing the prior layer to melt back again. Because of the unique thermal cycle, this results in residual stress (RS). The unique thermal cycle of metal additive manufacturing is characterized by (1) rapid heating rate caused by high energy intensity and steep temperature gradients; (2) rapid solidification with high cooling rates because of the small volume of melt pool; and (3) melt back, which involves simultaneous melting of the top powder layer and re-melting of underlying previously solidified layers. The presence of RS in metal additive manufacturing (AM) creates difficulties that restrict the process's ability to produce parts at an industrial scale. During and after manufacturing, these forces may cause parts to distort and crack. This can be solved by heating the powder bed, which will lessen this type of issue. The causes, traits, and reduction of RS are the main topics of this review article. A number of conceptual approaches to reducing RS are addressed to provide some useful inspiration for creating a methodical RS balancing procedure for AM. These approaches are based on the state and future of the relevant techniques.

Prestrain in the eardrum investigated using laser-ablation perforation: A proof of principle study on the New Zealand white rabbit

While the presence of residual stress (also called prestress) in the tympanic membrane (TM) was hypothesized more than 150 years ago by von Helmholtz (1869), little experimental data exists to date. In this paper, a novel approach to study residual stress is presented. Using a pulsed laser, the New Zealand white rabbit TM is perforated at seven predefined locations. The subsequent retraction of the membrane around the holes is computed using digital image correlation (DIC). The amount of retraction is the so-called prestrain, which is caused by the release of prestress due to the perforation. By measuring the prestrain using DIC, we show that residual stress is clearly present over the entire rabbit TM surface. In total, fourteen TMs have been measured in this work. An automated approach allows tracking the holes’ deformation during the measurement process and enables a more robust analysis than was previously possible. We find similar strains (around 5%) as reported in previous work, in which slits were created manually using flattened surgical needles. However, the new approach greatly reduces measurement time, which minimizes dehydration artifacts. To investigate the effect of perforation location on the TM, the spatial decrease of the prestrain (α) around the perforation was quantified. Perforations inferior to the umbo showed the least negative α values, i.e., the most gradual decrease around the hole, and were the most consistent. Perforations on other locations showed more negative α values, i.e., steeper decrease in strain, but were less consistent across samples. We also investigated the effect of the holes’ creation sequence but did not observe a significant change in the results. Overall, the presented method allows for consistent residual stress measurements over the TM surface. The findings contribute to our fundamental knowledge of the mechanics of the rabbit TM and provide a basis for future work on human TMs.

Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study

Additive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecting the quality and functionality of 3D-printed parts. This study conducts a comprehensive finite element analysis (FEA) to investigate the material-dependent impact of key printing parameters on residual stress and warpage deformation in 3D printing. The research focuses on three distinct materials: polyetherimide (PEI), acrylonitrile butadiene styrene (ABS), and polyamide 6 (PA6). Various printing parameters are systematically varied, including printing temperature, printing speed, bed temperature, infill density, layer thickness, and infill pattern. The study employs the Taguchi L27 orthogonal array and employs the analysis of variance (ANOVA) statistical technique to assess the significance of the input parameters. The obtained results reveal that certain parameters exhibit a greater sensitivity to material differences, whereas the layer thickness parameter demonstrates a relatively lower sensitivity. Notably, infill density and printing temperature play a crucial role in reducing residual stress for PA6, while the infill pattern parameter proves to be a significant contributor to minimizing warpage deformation across all three materials. These findings underscore the importance of conducting material-specific analyses to optimize 3D printing parameters and achieve the desired quality outcomes while mitigating residual stress and warpage deformation.

Determination of residual stresses in metallic materials based on spherical indentation strain

Abstract A spherical indentation strain method was proposed to determine surface residual stress in this study. Through numerical simulation, the effect of the material properties and residual stress on the plastic zone around the indentation was investigated, and the ideal strain measurement region appropriate for diverse materials was identified. Meanwhile, the presence of residual stress in material will cause the strain increment in the strain measurement area near the indentation to change. Based on the relationship among strain increment, residual stress and material mechanical properties, the calibration equation of residual stress for different materials were established. A portable residual stress loading device was developed and combined with the indentation test to calibrate the 316 L and 304 stainless steel of nuclear welding joint material. The reliability of this method was verified, and it provides convenience for the calibration of the residual stress of stainless steel materials.

DETERMINATION OF RESIDUAL STRESSES IN PIPES

During production, operation, transportation, and aging of finished products, stresses occur in the pipe metal. As a rule, these residual stresses affect the quality of pipes. The presence of residual stresses in products can cause brittle fracture, cracking due to corrosion, reduced elasticity, warping, etc. The development of methods for managing residual stresses in metals and products is the realization of a powerful reserve for improving the quality of metal products, which means increasing the reliability of machinery. The question arises as to which method, convenient in production conditions, should be used to assess residual stresses. A simple and affordable method for estimating residual stresses is needed in production conditions. This paper presents a simplified method for estimating residual stresses in pipes. The purpose of the work is to improve and present a methodology for estimating tangential and axial residual stresses in cold-formed pipes and tubes after heat treatment according to the method of M.M. Davydenko. Research methods: M.M. Davydenko's method for cutting rings and cutting strips from pipes. Calculation of residual stresses. Results. The method for estimation of tangential and axial residual stresses in pipes after cold deformation and after heat treatment is improved and presented. The formulas for calculating residual stresses are given. Practical value. Pipe plants need to estimate residual stresses to develop technological processes for the manufacture of new types of pipes and to meet pipe standards. The improved and presented methodology will help manufacturers in assessing residual stresses. Conclusions. Modern methods for assessing residual stresses have been considered. A methodology for calculating tangential and axial residual stresses according to M.M. Davydenko by cutting rings and cutting strips from the metal of the studied pipes is presented. The methodology is officially registered, which allows it to be used for official assessment of pipe quality.