Residual Stress Field Research Articles

Development and experimental validation of a thermo-metallurgical-mechanical model of the laser metal deposition (LMD) process

The current paper presents the development and experimental validation of a thermo-metallurgical-mechanical model for a multi-pass Laser Metal Deposition (LMD) process, with the objective of accurately predicting the resultant constituent phases and residual stresses. The thermal model is calibrated using temperature readings and is shown to accurately capture the transient temperature field and extent of the fusion zone associated with the multi-pass LMD process. The metallurgical model incorporates the kinetics of ongoing solid-state phase transformations (SSPTs) and tempering reactions. The predictions are validated via hardness measurements, demonstrating a very good agreement with the predictions. The developed mechanical model predicts the residual stress field, which is validated using X-ray diffraction measurements, and the comparison also shows a very good agreement between the predictions and measurements. The validated numerical model is then used to explore alternative LMD strategies showing that the choice of deposition strategy can significantly impact resultant constituent phases and residual stresses.

Iterative Stress Reconstruction Algorithm to Estimate Three-Dimensional Residual Stress Fields in Manufactured Components

Abstract Residual stress (RS) significantly impacts the mechanical performance of components. Measurement of RS often provides incomplete data in terms of components of stress and spatial density. Employing such fields in finite element simulations results in significant modification of the field to achieve equilibrium and compatibility among strains. To overcome this, an iterative stress reconstruction algorithm (ISRA) is developed to estimate 3D RS fields that satisfy equilibrium, are stress component-wise complete, and represent the characterized data sampled. An Al 7075-T651 plate and an additively manufactured (AM) A36 steel wall are considered for RS reconstruction using measurement data from the literature. A maximum variation of ∼2.5 MPa in the Al plate, and ∼10 MPa in the steel wall are observed between the reconstructed and measured stresses. Furthermore, unknown stress components emerge and reach significant magnitudes (upto ∼2.3 MPa in the Al plate and ∼45 MPa in the AM wall) during ISRA. Indeed, it is found that minor errors in measurement or data processing are eliminated through the physical requirements during ISRA. Employing a reconstructed RS field is hence not just more accurate given its compatibility, but it additionally corrects for minor errors in measurement. Furthermore, it is found that spatially dense measurement data result in convergence with fewer iterations. Finally, although ISRA yields a nonunique solution dependent on boundary conditions, measurement errors, fitting errors, and mesh density, it accommodates for uncertainties and inaccuracies in measurement, as opposed to failing to reach a physically realistic converged solution.

Formation of dual quasi-continuous networked structure and its strengthening effect in Ti-6Al-4V alloy reinforced with graphene via powder bed fusion

A dual-networked distribution of the reinforcements holds promise for achieving a balance between high-strength and moderate plasticity in titanium matrix composites (TMCs). Unfortunately, achieving this improvement in TMCs via additive manufacturing (AM) methods, presents significant challenges. Those challenges arise from the inherent differences in chemical and physical properties, which often led to agglomeration of the reinforcement and cracks caused by the high thermal residual stresses. To overcome those issues, this study focuses on the development of Ti-6Al-4V (Ti64) alloys incorporated with 0.5 wt% graphene nanosheets (GNSs) constructing a dual quasi-continued TiC network structure via powder bed fusion. The results exhibited a super-high tensile yield strength (1307 MPa), accompanied by a moderated elongation of 2.6% with reduced residual stress. The microstructure, phase contents, and mechanical performance were thoroughly investigated. A thermo-metallurgical-mechanical coupling model was developed, considering factors such as laser absorption effects and laser scanning strategy. Finally, a reasonable dual-network model was built to elucidate the contribution of various strengthening factors. Overall, this study illustrates that the strength of GNS/Ti64 composites is affected by the factors of GNS distribution, quasi-continue network in-situ TiC particles, temperature and residual stress field, offering a reference for fabricating high-strength nanocarbon/Ti64 composites by AM methods.

Prediction of martensitic transformation and residual stress field on 17–4 PH stainless steel fabricated by laser powder bed fusion

The 17–4 precipitation-hardened (PH) alloy can be printed into diverse microstructures. Existing reports on the alloy have focused on the effect of Creq/Nieq ratios and the processing parameters of laser powder bed fusion (LPBF) on the final microstructures of the δ-ferrite and α’-martensite phases in the alloy. However, the effect of microstructural variations on the residual stress field of LPBFed 17–4 PH stainless steel has not yet been investigated. This study bridges the gap between what is known about the microstructure and residual stresses by proposing an alloy-equivalent phase prediction diagram for the additive manufacturing of the 17–4 PH alloy by varying the Creq/Nieq ratio and volumetric energy density to control residual stresses via microstructure manipulation. Dilatometry and Satoh tests were performed to elucidate the mechanism of the offset effect in martensite transformation. To control the microstructures, samples were fabricated with various Creq/Nieq ratios (2.05, 2.15, 2.30, and 2.49) and laser powers (130, 150, 170, and 190 W). The 17–4 PH alloy exhibited a low Ms temperature and approximately net zero residual stresses in the Satoh test. The study confirmed that martensitic transformation, which occurs more readily at lower Creq/Nieq ratios and higher laser powers, effectively offsets tensile residual stresses during the LPBF process.

Analysis of circumferential CO2 arc welding welded shield machine hob to investigate the welding residual stress fields

Analysis of circumferential CO2 arc welding welded shield machine hob to investigate the welding residual stress fields

Determination of residual stress field in laser cladding using finite element updating method driven by contour deformation

Laser cladding is a cutting-edge technology widely used in additive manufacturing and surface modification. This process entails rapid melting and solidification driven by laser heating, which induces residual stress within the material. This study presents a data-driven approach to refine the numerical model of laser cladding, simultaneously emphasizing both the temperature characteristics and residual stress distribution within the thermomechanical coupling process. After integrating the residual stress distribution data obtained through the contour method with the molten pool morphology shaped by the thermal effects of laser cladding, a Levenberg-Marquardt optimization algorithm based finite element model updating scheme is proposed to efficiently identify the parameters of double ellipsoid heat source model, which employs parallel computing to reduce the computational time for iterations. The effectiveness of the proposed method is validated using experimental data. Moreover, this approach is adaptable, unaffected by the specimen size and shape, and can accurately predict the residual stress distribution characteristics. Therefore, it offers a robust framework for simulating the mechanisms of residual stress generation in titanium alloy laser cladding.

Fields of residual stresses near filled assemblage holes of the aircraft wing panel

Fields of residual stresses near filled assemblage holes of the aircraft wing panel

Derivation, characterization, and application of complete orthonormal sequences for representing general three-dimensional states of residual stress

Residual stresses are self-equilibrated stresses on unloaded bodies. Owing to their complex origins, it is useful to develop functions that can be linearly combined to represent any sufficiently regular residual stress field. In this work, we develop orthonormal sequences that span the set of all square-integrable residual stress fields on a given three-dimensional region. These sequences are obtained by extremizing the most general quadratic, positive-definite functional of the stress gradient on the set of all sufficiently regular residual stress fields subject to a prescribed normalization condition; each such functional yields a sequence. For the special case where the sixth-order coefficient tensor in the functional is homogeneous and isotropic and the fourth-order coefficient tensor in the normalization condition is proportional to the identity tensor, we obtain a three-parameter subfamily of sequences. Upon a suitable parameter normalization, we find that the viable parameter space corresponds to a semi-infinite strip. For a further specialized spherically symmetric case, we obtain analytical expressions for the sequences and the associated Lagrange multipliers. Remarkably, these sequences change little across the entire parameter strip. To illustrate the applicability of our theoretical findings, we employ three such spherically symmetric sequences to accurately approximate two standard residual stress fields. Our work opens avenues for future exploration into the implications of different sequences, achieved by altering both the spatial distribution and the material symmetry class of the coefficient tensors, toward specific objectives.

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.

Residual Stress Analysis of Re-autofrettage of a Swage-Autofrettaged Tube by Computer Modeling Incorporating Accurate Material Representation

Autofrettage processes allow engineers to reduce the thickness of thick-walled cylinders or components in high-pressure applications without sacrificing strength, life, or safety. However, during the autofrettage process, residual stresses will be generated due to plastic deformation. The complex tube material behavior is dominated by the Bauschinger effect. A better understanding and accurate prediction of the residual stress field is critical, which will enable better piping design strategies to minimize deformation and stresses under operating conditions. This study aims to predict and analyze residual stresses resulting from hydraulic re-autofrettage of a swage-autofrettaged thick-walled cylinder by computer modeling. A case study was performed on a thick-walled cylinder of A723 alloy with a radial interference of 2.5%. In order to investigate the effect of the chosen material constitutive representation, results based on the true material constitutive model were compared with the simplified prevalent material model of bi-linear kinematic strain hardening. Computer implementation for the true material was via a user-developed subroutine that incorporates the complex Bauschinger effect. The results indicate that an accurate material constitutive representation is crucial for better and more accurate prediction and understanding of residual stresses induced by autofrettage processes. Computer modeling based on the true material constitutive representation will likely prove to be a powerful tool for the design of autofrettage processes in general and thick-walled cylinders in particular.

Machine learning in prediction of residual stress in laser shock peening for maximizing residual compressive stress formation

Laser Shock Peening (LSP) is an advanced technique for enhancing surface properties, drawing significant interest for its ability to induce beneficial residual stresses in materials. Traditional LSP design processes, reliant on manual parameter selection, often result in imprecise control over the stress distribution, necessitating multiple iterations and high costs. This study introduces a machine learning (ML)-based approach, utilizing the Random Forest (RF) algorithm, to automate and optimize the design of LSP parameters for nickel-aluminium bronze surfaces. Our findings demonstrate the RF model’s capability to accurately predict and optimize residual stress distributions, achieving compressive stresses up to 472 MPa with a notable reduction in design iterations. The model forecasts both uniform and non-uniform stress patterns, particularly identifying areas susceptible to Residual Stress Holes (RSH) with improved precision. With an Absolute Percentage Error (APE) of only 6.2 %, our approach significantly outperforms traditional ML algorithms, offering a novel method for efficiently designing complex residual stress fields in LSP applications.

Influence of double-side symmetric oblique laser shock peening on shape deviation, surface integrity, and fatigue properties of the blades in small-sized blisk

Double-sided symmetric oblique laser shock peening (DSOLSP) was adopted to experiment on a small-sized blisk with restricted space. The influences of different laser energies on the shape deviation, surface roughness, microhardness, and residual stress of the blades were studied. The optimum process parameters were selected based on the shape deviation results of the blades and the microstructural evolution of the surface layers was investigated. The strengthening effect of DSOLSP treatment on notched blades was evaluated by vibration fatigue tests. It was found that DSOLSP can effectively cover the fatigue vulnerable regions without interference. Two-way bending deformation was formed after DSOLSP, and the shape deviation of the blades could be controlled within ±0.02 mm. With the increase of laser energy, the surface roughness and the depth of work-hardened layer increased. The full-thickness compressive residual stress (CRS) field was induced. A gradient microstructure was generated on the surface of the blade, and the size of average nanograins on the topmost surface is approximately 36.5 nm. The fatigue strength of the DSOLSP treated blades with notches was increased by 25.9 %. The enhancement can be attributed to the synergistic strengthening of CRS and gradient microstructure.

Evidence of microstructural evolution linked to non-monotonic distribution of micromechanical properties induced by shot peening

The residual stress field induced by surface strengthening processes such as mechanical shot peening and other forms of plastic deformation does not generally exhibit a simple “monotonic” distribution trend. Some researchers have analyzed this fact from a mechanical perspective based on Hertz theory. However, the micro/nano-scale microstructural changes corresponding to the distribution of residual stress fields still appear to be lacking. In this study, we focused on a widely used material in aviation manufacturing, namely nickel-based superalloy GH4169, as our experimental material. We subjected GH4169 alloy to mechanical strengthening treatment using a shot peening intensity of 0.25 mmA, followed by quantitative testing of micromechanical performance indicators such as microhardness and residual stress. To thoroughly investigate the relationship between micromechanical properties and microstructure changes, we utilized transmission electron microscopy (TEM) to observe and analyze shot-peened materials at different depths. Our findings revealed that the most severe microstructural distortion induced by mechanical shot peening in GH4169 alloy was likely to occur within a depth range of 25 to 75 µm. This observation aligns with the actual phenomenon that the maximum microhardness and maximum residual compressive stress did not manifest on the outermost surface of the material. By presenting a detailed analysis of deformation defects such as dislocations, stacking faults, and twinning in different depths of mechanically strengthened layers, our study contributes to a deeper understanding and practical application of post-processing technologies based on plastic deformation.

Improvement of fatigue life of Ti-6Al-4V alloy treated by double-sided symmetric oblique laser shock peening

To improve the anti-foreign object damage (FOD) ability of Ti-6Al-4V alloy blisk blades, a blade simulation specimen was designed and subjected to double-sided symmetrical oblique laser shock peening (DSOLSP) treatment. Surface roughness, residual stress distribution, and microstructural evolution of simulated specimens of Ti-6Al-4V alloy without and with DSOLSP were investigated, and the strengthening effect was evaluated by flexural fatigue test. The results showed that after DSOLSP treatment, surface roughness of simulated specimens was reduced from Ra0.97 µm to Ra0.6 µm. DSOLSP treatment generated a compressive residual stress (CRS) field along the entire thickness direction of the simulated specimen. Nanostructures with a depth of ∼500 nm was observed at topmost surface layer, and the average size of the nanograins was about 35.2 nm. Compared with the base material, the flexural average fatigue life of the simulated specimen was increased by 8.45 times. Moreover, mathematical statistical analysis confirms that DSOLSP has a significant effect on the fatigue life of simulated samples. The development of CRS fields throughout the entire thickness direction, the grain refinement on the surface, and the reduction of surface roughness are primarily responsible for the enhancement of the flexural fatigue life of the DSOLSP simulated specimen.

Identifying multiple synergistic factors on the susceptibility to stress relaxation cracking in variously heat-treated weldments

The 347H austenitic stainless steel has been widely used for pressure vessels and pipeline (PVP) applications due to its excellent creep and corrosion resistance, which fit ideally to the harsh conditions in petrochemical industries, fossil fuel or nuclear power plants, and modern energy storages. However, a failure mode has been commonly observed with cracks emerging at the heat affected zone (HAZ) of weldments during post-weld heat treatment (PWHT) or under intermediate to high temperature service conditions. This phenomenon is termed as Stress Relaxation Cracking (SRC) since the purpose of PWHT is to relieve the welding-induced residual stress fields, or as Stress Age Cracking (SAC) if failure happens during service. A leading literature explanation of this failure suggests that the residual stress relaxation and the precipitation dissolution and/or re-precipitation occur in the same temperature range, which can lead to locally high strains and thus to crack at the grain boundaries. Since in situ spatial measurements of residual stress fields, microstructural evolution, and failure processes are nearly infeasible, this work recourses to a micromechanical finite element framework that models the high temperature failure as the nucleation and growth of grain boundary cavities, whereas various parameters such as thermomechanical loading history and its evolution, the competition of grain-interior dislocation creep and grain-boundary diffusion in failure lifetime, and microstructural heterogeneities (such as the precipitate free zone near grain boundaries) can be quantitatively incorporated. It can be concluded from these microstructure-explicit simulations that an accurate knowledge of residual stress evolution and a carefully calibrated set of material constitutive parameters are the essential prerequisites for lifetime predictions. The understanding of individual governing factors also leads to a mechanistic interpretation of the observed SRC susceptibility C-curves. These results suggest that the criticality of residual stress evolution, but not the precipitation-induced local strains, be the leading factor for SRC.

Gradient residual stress and fatigue life prediction of induction hardened carbon steel S38C axles: Experiment and simulation

Gradient distribution of triaxial residual stresses to a depth of several millimeters is retained in middle carbon steel S38C axles after high-frequency induction hardening, which has become a critical concern for fatigue structural integrity. To address this, the axial, hoop, and radial gradient residual strains inside the axles were measured for the first time by advanced neutron diffraction. The SIGINI Fortran subroutine was then adopted to reconstruct the global initial residual stress field from the measured data. Experimental and simulation results show that residual stresses of about −520 MPa (axial), −710 MPa (hoop), and −40 MPa (radial) residual stress were retained below the axle surface. Subsequently, the fatigue crack propagation behavior of S38C axles was numerically investigated in the framework of fracture mechanics. The calculated results clearly show that the compressive residual stresses at a depth of 0–3 mm from the axle surface lead to a low crack growth driving force, and that fatigue cracks do not propagate as long as the crack depth is less than 3.7 mm for hollow S38C axles. These results further indicate that the maximum defect size allowed in routine inspections is acceptable from a safety and economic point of view. Accurate measurement and characterization of the global gradient residual stress field through experiments and simulations can provide an important reference for optimizing the mileage intervals of nondestructive testing (NDT) of surface defects in these surface-strengthened railway axles.

Numerical study of full penetration single- and double-sided U-rib welding in orthotropic bridge decks

Under the repeated action of residual stress and wheel load caused by welding, fatigue cracks easily occur on the top plate-U rib welding of an orthotropic bridge deck (OBD). These affect the service life. To study the influence of different full-penetration welding methods on the residual stress and fatigue of OBD, this study compared the residual stress, welding deformation, and fatigue performance of full-penetration single- and double-sided welding through finite element analysis. The welding temperature and residual stress fields were simulated based on Goldak's double ellipsoid heat source model using the thermal elastic-plastic method. The numerical results were verified using measured data from relevant literature, and the two were in good agreement. The results showed that the longitudinal residual stress of the double-sided welded U-rib was larger than that of the single-sided welded U-rib, primarily in the compressive stress range, and the maximum deviation reached 99.44 MPa. The longitudinal displacement of single-sided welding along the weld direction was 0.060 mm lesser than that of double-sided welding, and the maximum vertical displacement perpendicular to the weld direction was 2.457 mm lesser than that of double-sided welding. For the same frequency of fatigue load (wheel load), the fatigue strength of single-sided welding was larger than that of double-sided welding, and the fatigue life increased by 29.7%. In this study, analysis models of the full-penetration single-sided and full-penetration double-sided welding were established, which could provide a reference for structural fatigue assessment using the two full-penetration welding techniques under the influence of residual stress.

Nanostructure characterisation of welded polyethylene using small angle X-ray scattering

Polyethylene (PE), a common thermoplastic polymer, is gaining prominence in the construction and packaging industries due to its exceptional mechanical properties, chemical resistance, safety, and integrity. However, internal defects can occur during manufacturing and throughout its service life. Neglecting this problem results in the disposal of plastic and, consequently, the accumulation of plastic waste and environmental issues, which have caused much criticism. A common method to repair the thermoplastics is welding, which introduces seams and localized thermal residual stress fields resulting in areas where damage can nucleate, potentially leading to cracks and failure over time. These cracks often start at the nanoscale and propagate to larger length scales until failure occurs. The objective of this research paper is to develop welding processes, with improved integrity and lifespan for PE. Additionally, it aims to investigate and assess the impact of PE welding on parent materials at nano- and micron-scales, to understand limitations that are challenging to overcome in such welding processes. The study involves joining PE panels together under various pre-heating and post-cooling conditions, followed by evaluating the environmental stress cracking resistance of the welds and the durability of the repaired components. The crystallinity and morphology of the PE material in the weld area and its surrounding regions were analysed using Small Angle X-ray Scattering (SAXS), and the findings were compared with results obtained from optical microscopy and Differential Scanning Calorimetry. The study concludes that SAXS results offer exceptional information about the parent PE and weld material within the welding zone.

Digital simulation of distortion-induced fatigue in steel bridges with different geometrical configurations

Distortion-induced fatigue cracks at web gaps often occur in multi-girder steel bridges under vehicle loads. This paper presents full size digital simulations of steel girder bridges with different geometrical configurations, to explore the distortion-induced fatigue cracking performance. In the digital simulations, four geometrics are considered, in addition to two web gap details, namely the vertical stiffener web gap and the horizontal gusset plate web gap. Introducing multi-layer and multi-pass welds residual welding stress fields, digital fatigue simulation results show that the distortion-induced fatigue cracks at both web gaps are Mode I-II-III combined cracks dominated by Mode I. The coupling of the three modes is more prominent at the vertical stiffener web gap compared to the horizontal gusset plate web gap. In the skewed bridge, curved bridge, and skewed-curved bridge, the significant bending-torsional coupling effect, the structural asymmetry, and the stress deformation asymmetry cause an increment in distortion ranges, fatigue crack growth rates, and the proportions of Mode II and III cracks. The fatigue strength categories for vertical stiffener web gap and horizontal gusset plate web gap in straight, skewed, curved and skewed-curved bridges are category 125, 112, 110 and 110, and category 160, 140, 100 and 100 of the Chinese specification and Eurocode, respectively. Therefore, the geometrical configuration is an important factor affecting the distortion-induced fatigue behavior, which should be considered in the fatigue design and maintenance of steel girder bridges.

Simulation study on effect of flame cutting speed on temperature field and residual stress distribution

Due to the advantages of flame cutting in thick plate cutting and cutting cost, it is widely used in the metal cutting process of shipbuilding and machinery manufacturing. But at the same time, the local heating of flame cutting will cause residual stress inside the steel plate. Residual stress is an important reason for deformation and cracking of components. The change of temperature field is the premise of affecting the distribution of residual stress. Cutting speed has an important effect on the distribution of temperature field and residual stress field. In this paper, ABAQUS is used to create a finite element model for flat flame cutting of Q345D low-alloy steel. Based on the working principle of flame cutting, the model of flame cutting composite heat source is established and the subprogram of composite heat source is written. The thermal-mechanical direct coupling method is used to simulate and analyze the effect of different cutting speeds on the temperature and residual stress field distribution of the flat flame cutting process, to provide a reference for the subsequent processing.