Presence Of Residual Stresses Research Articles

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.

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.

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.

Application of sensitivity analysis in extension, inflation, and torsion of residually stressed circular cylindrical tubes

This paper deals with applying two main sensitivity analysis (SA) methods, namely, the Sobol method and the Fourier Amplitude Sensitivity Test (FAST) method on the problem of mixed extension, inflation, and torsion of a circular cylindrical tube in the presence of residual stress. The mechanical side of the problem was previously proposed by Merodio & Ogden (2016). The input parameters in the form of the initial cylinder geometry, the amount of the residual stress, the azimuthal stretch, the axial elongation, and the torsional strain are distributed according to three probability distribution methods, namely the uniform, the gamma, and the normal distribution. In the present work, through applying Sobol and FAST methods, the most influential factors among input parameters on the output variable have been determined. The assessment of our results is then determined by the computation of bias and standard deviation of Sobol and FAST indices for each input parameter in the model.

Effects of nonproportional loading and residual stress on creep crack tip fields

Nonproportional loading and residual stresses effects on creep crack tip fields are important topics in fracture mechanics at elevated temperature. In this paper, nonproportional loading and residual stresses effects on creep crack tip fields are systematically investigated based on the novel interpretation of C(t)-integral considering residual stress. With the numerical implementation of the corrected C(t)-integral considering residual stress, the eigenstrain and mechanical induced residual stress effects on the creep crack tip fields are studied. We find that C(t)-integral level is affected remarkably in the presence of residual stress regardless of eigenstrain or mechanical induced residual stresses for creep crack tip under small scale creep. However, level of C*-integral is not significantly influenced under the effects of residual stresses in presence of large-scale creep although the transition creep time is remarkably changed. Otherwise, C(t)-integral is highly affected by loading path under small scale creep. However, C*-integral is independent of the loading path if the creep time is long enough. Nonproportional loading effect on C*-integral is very limited for creep crack tip field according to our study. The investigation given in this paper could deepen the understanding the effects of residual stress and nonproportional loading on the creep crack tip field.

Analysis of the possibility of using additive technologies in basic parts manufacturing

The purpose of the article is to choose a selective laser sintering method suitable for basic parts manufacturing, as well as to analyze mechanical characteristics of parts obtained using selective laser sintering, depending on the technology of their production. Basic parts manufacturing is a complex and expensive process which includes casting or welding, milling of base surfaces, and boring of holes. As a rule, body is the largest part of the structure, and accuracy of its base surfaces manufacturing directly affects performance of the entire mechanism. Method of producing blank parts is of paramount importance in body manufacturing. Parts of this type must ensure precision of the relative position of individual elements, both at rest and in the dynamic mode of machine operation. At the same time, it is known that all methods of blank parts production are characterized by the presence of residual stresses in the blank part. Gradually relaxing, these stresses “come out” in the form of deformations, which leads to displacement of parts and units of the entire mechanism, and a change in their interaction. This directly affects performance and resource of the entire machine.

Experimental and Numerical Study of Thermal Residual Stresses on Multimaterial Adherends in Single-Lap Joints.

The presence of residual stresses in composite materials can significantly affect material performance, especially when integrated in bonded joints. These stresses, often generated during the cure process, can cause cracking and distortion of the material, and are caused by differences in the coefficients of thermal expansion or cure shrinkage. In the current research, multimaterial adherends combining carbon-fibre-reinforced polymer (CFRP) and aluminium in a single-lap joint (SLJ) configuration are analysed, allowing us to understand the effect of the thermal residual stresses, developed during the curing process, in the overall performance of the joints. A numerical model resorting to a finite element analysis (FEA) is developed to assess and predict the behaviour of the joints. The use of FML (fibre metal laminates) was found to significantly improve the strength of the joints, as well as the failure mode. The proposed geometry performed similarly to the comparable FML geometry, in addition to a decrease in the joint weight.

Magnetic properties of Fe–Si–B thin films and their application as stress sensors

• As deposited sputtered thin films stress can be designed. • Amorphous FeSiB thin films have magnetic properties stress-dependent. • Permeabilities are larger for the tensile stress region than in the compressive stress region. • Stress is reducing the permeabilities of the thin films. • Amorphous FeSiB thin films can be candidates for Stress Impedance sensing systems. This study aimed to understand the magnetic behavior of amorphous Fe–Si–B thin films in the presence of residual stress. Residual stress appeared in the thin films during the sputtering process, which was controlled by changing the Ar flow rate during sputtering. Consequently, some thin films developed compressive stress and others developed tensile stress. The residual stress generated in the films ranged from –100 to 400 MPa. The magnetization curves of the samples were measured to extract their magnetic parameters, namely, the magnetic permeability, coercive field, and saturation magnetization. For the films of thickness 500 nm, the relative permeability was higher under tensile stress ( µ r ∼ 1000) than under compressive stress ( µ r ∼ 100). A transition between the high and low permeability values occurred for residual stress in the range 0–100 MPa. The relative permeability decreased from 1100 to 800 as the tensile stress increased from 0 to 400 MPa. In addition, the relative permeability decreased from 150 to 100 as the compressive stress increased from 0 to –100 MPa. Moreover, a transcritical state was observed in the samples under compressive stress. For the films of thickness 200 nm, the tensile stress lowered the relative permeability from 800 to 400; however, the compressive stress did not change the permeability significantly.

Residual stress influence on fatigue crack propagation of CFRP strengthened welded joints

In order to take into account the influence of welding residual stresses on fatigue crack growth, thermo-elastic-plastic finite element models of steel cruciform welded joints were developed by the ABAQUS software. The distribution and magnitude of longitudinal and transverse residual stresses were obtained in consideration of different welding currents and speeds. Uniaxial tensile fatigue tests on cracked cruciform joints strengthened with carbon fiber reinforced polymer were conducted. The coupling actions of residual stresses and fatigue loads were applied to subsequently simulate fatigue crack propagation via using the Extended Finite Element Method. Good agreement between the simulated and theoretical transverse residual stresses at the weld toe along the plate thickness direction verifies the accuracy of numerical results. The welding speed has a greater impact on residual stresses than the welding current. The stiffness ratio of carbon fiber reinforced polymer and steel plate is larger, and a better reinforcement effect will be achieved. Whether specimens repaired or not, it significantly decreases the fatigue life of cracked welded joints in the presence of residual stresses, but the fatigue crack growth trajectory is almost unchanged.

Selective Laser Melting of Ti6Al4V: Effects of Heat Accumulation Phenomena due to Building Orientation

Titanium alloy Ti6Al4V is one of the most utilized alloys in the field of additive manufacturing due to the excellent combination of mechanical properties, density and good corrosion behavior. These characteristics make the use of this material particularly attractive for additively manufacturing components with complex geometry in sectors such as aeronautics and biomedical. Selective Laser Melting (SLM), by which a component is fabricated by selectively melting of stacked layers of powder using a laser beam, is the one of most promising additive manufacturing technologies for Ti6Al4V alloy. Although this technique offers numerous advantages, it has some critical issues related to the high thermal gradients, associated with the process, promoting the formation of a metastable martensitic microstructure resulting in high tensile strength but poor ductility of the produced parts. The formation of microstructural defects such as balling and porosity can occur together with the presence of residual stresses that may significantly affect the mechanical characteristics of the component. Specific process parameters and geometries can determine heat accumulation phenomena that result in a progressive decrease in thermal gradients between layers. These heat accumulation phenomena are influenced by the number of layers deposited, but also by the building orientation that, for a given geometry, determines a variation of the deposited surface for each layer.

Possibility of estimation of mechanical stresses in nickel by the magnetic ponderomotive method

The paper considers a technique for assessing mechanical stresses in coatings by the magnetic ponderomotive method, based on the use of the magnitude of the magnet breakaway force and its relation to the magnetic characteristics of nickel (magnetic susceptibility), which change under the action of internal stresses. It is shown that the existing mechanical stress measuring equipment using X-ray, magnetic or ultrasonic methods have specimen size limitations or have low measurement locality. At the same time, a magnetic ponderomotive method for controlling mechanical stresses is presented, which does not have the indicated disadvantages. The change in the magnetic breakaway force on the thickness, applied and residual stresses caused by elastic and plastic deformations in the sample is theoretically substantiated. It is shown that the presence of residual stresses in the sample changes the nature of the dependence of the magnet breakaway force on the applied stresses. A calculation algorithm has been developed that allows measuring the magnet breakaway force to obtain the ratio between the applied and residual stresses. It is shown that the ratio between residual and applied stresses can be used to assess the degree of proximity to the critical stresses levels that lead to failure. Calibration surfaces are constructed for the dependence of applied stresses on magnetic separation force and thickness, corresponding to elastic-plastic deformation, as well as leveled calibration surfaces, corresponding to elastic deformation in the presence of residual stresses in the material. Experiments have been carried out on real samples and coatings, that determine the degree of approximation of internal stresses in the material to critical levels that may lead to destruction. It is shown that when comparing the readings of calibrated gauges with a certified tool, the largest deviation occurs at low stress values due to the inverse dependence of the breakaway force on the stress level.