Formation Of Residual Stresses Research Articles

Effect of Preliminary Heat Treatment on the Formation of Structure and Residual Stresses in the AMg6 Alloy at Laser Shock Peening Without Coating

Effect of Preliminary Heat Treatment on the Formation of Structure and Residual Stresses in the AMg6 Alloy at Laser Shock Peening Without Coating

A Numerical Investigation About Shrink Line Formation in TPMS Lattice Structures During LPBF Process

Thermal nature of laser powder bed fusion process (LPBF) causes residual stress formation on the part during printing which may cause penetration of some layers towards inside or outside of the nominal geometry called shrink line. Shrink line affects dimensional accuracy and fatigue life of produced parts. The prediction of shrink line formation via numerical methods is important to mitigate the high cost of trial-and-error printing. This study focused on shrink line formation prediction in triply periodic minimum surface (TPMS) lattices produced by LPBF process. The effect of TPMS type, volume fraction, unit cell size, inclination angle of the lattice with respect to build platform, functional grading and material on shrink line formation were investigated. Numerical results revealed that shrink lines were formed only on Primitive lattices and input or control parameters used in this study directly influence the shrink line penetration depth due to different thermally induced stress formation between successive layers.

Residual Stress Formation and Distortion in Austenitic AISI304 Steel Pipe Weldment with Consideration of Latent Heat using Novel Prescribed Weld Temperature

Residual Stress Formation and Distortion in Austenitic AISI304 Steel Pipe Weldment with Consideration of Latent Heat using Novel Prescribed Weld Temperature

A comparative analysis of compressive and wear failure of laser-powder bed fused Stainless Steel 316L produced with different hatch spacing in stripe and contour patterns

The selection of hatch spacing is crucial in additive manufacturing processes to produce a defect free Stainless Steel 316L (SS) components, especially in laser powder bed fusion (LPBF) process. Improper selection of hatch spacing could lead to various failure regimes (like vertical cracking, porosity, and un-melted particles) in Stainless Steel 316L (SS) component produced through laser powder bed fusion (LPBF). Further, the failure regimes have a direct impact on the hardness, compression strength, friction, and wear properties of LPBF SS components. The present study has taken substantial efforts to analyse the impact of various hatch spacing (0.08 mm, 0.10 mm. and 0.12 mm) in stripe and contour patterns, in terms of morphology, mechanical, and tribological properties of LPBF SS components. Also, the present study elucidates how variations in hatch spacing influences the features like particle fusion, crack formation, density, hardness, surface roughness, compression, and wear properties. The stripe pattern with low hatch spacing of 0.08 mm showed better particle fusion and high surface roughness; whereas the high hatch spacing has produced voids, un-melted powder particles, and cracks in the stripe and contour pattern. High densities and hardness values were attributed to the stripe patterns with more effective melting and fusing of powder particles. XRD analysis revealed the stable phase compositions across various hatch spacing with a predominant FCC crystal structure. Residual stress distribution was significantly influenced by the hatch spacing for both stripe and contour patterns. Importantly, the low hatch space leads has promoted the tensile residual stress formation and vice versa for the higher hatch spacing. Stripe patterns showed higher compression strengths with buckling and shear mode as a compression failure. The stripe pattern demonstrated a low specific wear rate (SWR) and coefficient of friction (COF) compared to the contour pattern, with respect to the various hatch spacing. Furthermore, the simulated body fluid (SBF) lubrication regime played a significant role in reducing the COF. Patches, groves, furrows, and craters demonstrated the abrasive and adhesive failure for both stripe and contour pattern, which is further detailed in the article.

Role of residual stress in the failure of HF-ERW welded tubes

High-frequency electric resistance welding is used for manufacturing hydro formable tubes. Tube forming and welding results in the formation of residual stress. The hole drilling technique was used to evaluate the residual stress of the welded tube. Tensile residual stress of varying magnitude was observed at different locations on the tube. The weld, heat affected zone was observed to have the highest residual stress as a result of phase transformation, forming and gradually reduced towards the parent material. The generated tensile residual stress led to failure of the tube during mechanical evaluation. Additionally, electron backscattered diffraction studies (EBSD) of the fusion line and the thermo-mechanically heat-affected zone were found to have goss and cube texture. These detrimental textures can lead to easy crack propagation in the presence of defects along the fusion line. A post-weld heat treatment (PWHT) was carried out to alleviate the tensile residual stress and alter the weld microstructure. PWHT helped transform the bainite in the weld to ferrite and pearlite. The inter-critical annealing significantly reduced the tensile residual stress along the circumferential direction resulting in improved formability.

A framework to efficiently simulate the cyclic variation of the residual stresses induced by chip formation in machining of Ti-6Al-4 V alloy

Residual stresses is a key part of surface integrity, having a strong influence on the functional performance and lifespan of components. Advances in modeling of machining-induced residual stresses are fundamental to achieve more accurate predictions. Due to the low computational efficiency and the lack of consideration of the whole residual stress formation process, a framework to simulate the residual stress in the machining of Ti-6Al-4 V titanium alloy using CEL (Coupled Eulerian and Lagrangian) and Lagrangian approaches is proposed. A model of the cutting and workpiece unloading processes is simulated using CEL approach and explicit time integration scheme. Then, a model of the cooling process of the workpiece is developed in order to calculate the residual stresses. To improve computation efficiency and to reduce the effects of cumulative errors, this model is simulated using Lagrangian approach and implicit time integration scheme. Data transfer between these two models is performed by combining a strategy of data transfer and mesh rebuilding. The cutting force and residual stress are obtained by simulation with average errors of 18% and 21%, respectively. The predicted and measured thicknesses of the layer are reasonable well predicted. The computational time of proposed approach can be greatly reduced from 81 h to 5.3 h by comparison with traditional one. This framework was then used to investigate the cyclic variation of the residual stress along the cutting direction, which is due to the cyclic nature of the chip formation process.

Multi-physical simulation of an inductive heat treatment process on 50CrMo4 steel rods and validation by HEXRD cross-sectional measurements

A multi-physical finite element model for the induction hardening of a 50CrMo4 steel rod was implemented in Abaqus, including an electromagnetic, thermal, mechanical, and metallurgical model describing the individual phenomena taking place during the process. For induction heating, a linearization scheme for the nonlinear permeability of steel was implemented. The model was validated by recreating a previously published experiment with the model and using the calculated residual stress data as a comparison to the measured stresses. To ensure a valid comparison, the sample preparation process and measurement methodology were considered for the simulation and a good agreement between the measured and calculated stress distributions was obtained. Thus the distribution and time evolution of several quantities such as temperature, phase fractions and plastic strain can be examined to gain insight into the formation of residual stresses.

Laser shock peening of laser melting deposited TiAl alloy for enhancing its corrosion resistance

Laser shock peening (LSP), as a post-treatment process, was employed to improve the corrosion resistance of Ti45Al8Nb alloy fabricated via laser melting deposition (LMD). Microstructure analysis indicated that nanograins and nanotwins structures were formed on the surface layer of LSP-treated Ti45Al8Nb alloy, accompanied by high-density dislocations and stacking faults. Electrochemical results showed that LSP improves the corrosion resistance of Ti45Al8Nb alloy. The formation of nanograins, nanotwins and compressive residual stress during LSP was conductive to dense oxidation films, thus improving the corrosion resistance of the as-deposited Ti45Al8Nb alloy.

Influence of rapid high-temperature processing on the interface of CF/PEEK, a quick and effective method for enhancing the IFSS

This study explores the effect of rapid high-temperature processing on the interface of carbon fibre (CF) reinforced poly-ether-ether-ketone (PEEK). Specimens that have been thermally treated at slower and faster heating rates and specimens that have not been post-manufacturing treated (virgin) are examined with single fibre pull-out tests. A comparison between their interfacial shear strength (IFSS) and their failure modes takes place. Scanning electron microscopy is used to assess the surface morphology of the thermally treated specimens, and partly cross-polarised microscopy is employed to investigate the development of transcrystallinity. Furthermore, to identify the extent of thermal degradation the specimens are examined with attenuated total reflection Fourier transform infrared spectroscopy. At faster heating rates, an improved interfacial adhesion up to 25% is found at temperatures where a low-level thermal damage is induced. At higher temperatures and despite the increased thermal damage, an IFSS increase of up to 10% is still identified. This is due to the beneficial formation of thermal residual stresses upon high-temperature processing, and overall, especially rapid high-temperature processing could effectively serve for enhancing the interface properties of CF/PEEK.

Material migration and damage characteristics of fused silica optical surface treated by CO2 laser/short – pulse ultraviolet laser

Fused silica optics, as key components in high - power laser systems, are prone to be damaged under short - pulse ultraviolet (UV) laser irradiation. CO2 laser is usually used to repair the laser damage and extend the service life of optics. However, the anti - laser damage characteristics of repaired substrates sometimes can’t meet the expectation. To facilitate better application of CO2 laser repairing method, this work studied the CO2 laser irradiating mechanism of fused silica in detail and investigated the damage characteristics of repaired optical surface through experiments. Firstly, finite element level - set (FELS) method is adopted to simulate CO2 laser irradiating process. The simulation showed that CO2 laser irradiation would cause molten material migration, vapor material deposition and affect the formation of residual stress. Various tests of morphology, residual stress, and photo - thermal absorption were conducted to study the changes of laser damage characteristics of repaired craters. The experimental results presented that molten materials migration and vapor materials re deposition occurred in CO2 laser irradiation, which would promote the formation of residual stress, cause stronger laser absorption, or even induce laser damage. Through the experiment, accuracy of simulation was verified further. In this work, the CO2 laser repairing mechanism of fused silica and laser damage characteristics of repaired optics are clarified through FELS simulation and experiments. Relative results can provide a certain technical support for the performance improvement of repaired fused silica optics.

Multi-field coupling numerical simulation and experimental research of submerged arc surfacing process on the descaling rolls with different wall thickness

Iron and steel industry descale rolls long-term high-pressure water erosion, high temperature, easy to wear, corrosion failure and other problems, the continuous production of steel rolling impact, descale rolls base wall thickness is the main cause of cracking of the surfacing gradient lap organization. This article combines numerical simulation and experimental testing, the use of CALPHAD method to calculate the surfacing material temperature change physical parameters, based on the double ellipsoid heat source model, the establishment of the descale roller submerged arc surfacing process of multi-field coupling three-dimensional numerical model, calculations and reveal the descale roller submerged arc surfacing process of the temperature field, the stress field, the phase change field and the flow field of the transient evolution of the law, and further analyze the descale roller wall thickness of the surfacing process of the influence of the mechanism. Calculation results show that the depth of melting of the surfacing matrix is positively correlated with the width of the double ellipsoid heat source, and the larger the wall thickness, the faster the cooling rate, the greater the formation of residual stress. The austenite and martensite phase transformation of the overlay welding process is greatly influenced by the wall thickness. At the same time, SEM, EDS, XRD material science microcharacterization experiments were carried out to observe the micro-morphology, phase and elemental composition of the cladding layer. This study lays an important theoretical foundation for optimizing the submerged arc surfacing process of descale roller.

Towards Understanding of the Plastic Zone Thermal Residual Stresses in Functionally Graded Materials

Abstract: Functionally graded materials (FGM’s) are advanced composites consisting of two or more materials whose composition and structure changes gradually over the volume, leading to gradual change in its property. Typically one component is a ceramic, while the other is metal or metal alloy. In common embodiments, the composition can change gradually from all ceramic on one side to all metal on the other side, the ceramic contributing high resistance to temperature with the metal contributing high ductility. It’s a way to incorporate favorable properties of two materials into different locations of a single structure. In ideal cases the composition changes gradually but for manufacturing reasons, the changes occurs in homogeneous layers. The boundaries between the layers cause thermal residual stresses to arise, especially during material processing and in cases of cyclic loading. These thermal residual stresses are a result of differences in the thermal expansion coefficient of the varying compositions of materials. Thermal residual stresses may lead to cracking and ultimate failure of FGM’s. This study investigates the formation of thermal residual stresses for a Nickel-Alumina Ni-Al₂O₃ FGM. The Ni-Al₂O₃ system is chosen because it is one of the most common systems used in practice. This work explores the formation, impact and minimization of thermal residual stresses for a number of practical conditions that may arise during processing. All relevant properties are calculated using the rule of mixture equations.

Minimizing the Formation of Thermal Residual Stresses of the Elastic Zone in Functionally Graded Materials

Abstract: Functionally graded materials (FGM’s) are advanced composites consisting of two or more materials whose composition and structure changes gradually over the volume, leading to gradual change in its property. Typically one component is a ceramic, while the other is metal or metal alloy. In common embodiments, the composition can change gradually from all ceramic on one side to all metal on the other side, the ceramic contributing high resistance to temperature with the metal contributing high ductility. It’s a way to incorporate favorable properties of two materials into different locations of a single structure. In ideal cases the composition changes gradually but for manufacturing reasons, the changes occurs in homogeneous layers. The boundaries between the layers cause thermal residual stresses to arise, especially during material processing and in cases of cyclic loading. These thermal residual stresses are a result of differences in the thermal expansion coefficient of the varying compositions of materials. Thermal residual stresses may lead to cracking and ultimate failure of FGM’s. This study investigates the formation of thermal residual stresses for a Nickel-Alumina Ni-Al₂O₃ FGM. The Ni-Al₂O₃ system is chosen because it is one of the most common systems used in practice. This work explores the formation, impact and minimization of thermal residual stresses for a number of practical conditions that may arise during processing. All relevant properties are calculated using the rule of mixture equations. Abaqus, a non-linear FEA solver, is used for all the simulation work. In addition, the study highlights the need for examining elasto-plastic analysis to illuminate the process of crack development which is our future research goal.

Finite Element Modeling of the Plastic Zone Thermal Residual Stresses in Functionally Graded Materials

Abstract: Functionally graded materials (FGM’s) are advanced composites consisting of two or more materials whose composition and structure changes gradually over the volume, leading to gradual change in its property. Typically one component is a ceramic, while the other is metal or metal alloy. In common embodiments, the composition can change gradually from all ceramic on one side to all metal on the other side, the ceramic contributing high resistance to temperature with the metal contributing high ductility. It’s a way to incorporate favorable properties of two materials into different locations of a single structure. In ideal cases the composition changes gradually but for manufacturing reasons, the changes occurs in homogeneous layers. The boundaries between the layers cause thermal residual stresses to arise, especially during material processing and in cases of cyclic loading. These thermal residual stresses are a result of differences in the thermal expansion coefficient of the varying compositions of materials. Thermal residual stresses may lead to cracking and ultimate failure of FGM’s. This study investigates the formation of thermal residual stresses for a Nickel-Alumina Ni-Al₂O₃ FGM. The Ni-Al₂O₃ system is chosen because it is one of the most common systems used in practice. This work explores the formation, impact and minimization of thermal residual stresses for a number of practical conditions that may arise during processing. All relevant properties are calculated using the rule of mixture equations. Abaqus, a non-linear FEA solver, is used for all the simulation work. In addition, the study includes an elasto-plastic analysis to illuminate the process of crack development.

Numerical modeling and statistical analysis of the effect of thermomechanical properties on residual stresses in feldspar‐based ceramic materials after thermal tempering

AbstractThis study focuses on the investigation of the impact of the thermomechanical properties of ceramic materials on residual stresses generated after the thermal tempering process. A sodium feldspar matrix was chosen for numerical simulations, with variations in its thermomechanical properties of up to ± 20%, to encompass a range of properties exhibited by other ceramic materials. The simulations demonstrated that the viscosity of the material had the most significant influence on residual stress generation, while the coefficient of thermal expansion, modulus of elasticity, and effective diffusivity also contributed to residual stress formation. A statistical analysis based on a 24 factorial design revealed that increasing residual compressive stress on the surface was achievable by increasing the coefficient of thermal expansion and modulus of elasticity, as well as the viscosity, while reducing the effective thermal diffusivity. Finally, a mathematical model was proposed to relate the thermomechanical properties of the ceramic material to the residual stresses observed on the surface following thermal tempering.

A hybrid radial basis function—Finite difference method for modelling two-dimensional thermo-elasto-plasticity, Part 2. Application to cooling of hot-rolled steel bars on a cooling bed

This paper represents Part 2 of the parallel paper Part 1, where the strong form hybrid RBF-FD method was developed for solving thermo-elasto-plastic problems. It addresses the industrial application of this novel meshless method to steel bars cooling on a cooling bed (CB) where the formation of residual stress is of primary interest. The study investigates the impact of the distance between the bars and the distance to the heat shield above the CB on radiative heat fluxes and, consequently, on thermo-mechanical response. The thermal model is solved on bars cross-section with a RBF-FD method where augmented polyharmonic splines are used for the local approximation. View factors, computed with a Monte-Carlo method, are included in radiative heat fluxes. The thermal solution is incrementally applied on a mechanical model that assumes a generalised plane strain state and captures bars bending. The study employs a hybrid RBF-FD method to resolve a nonlinear discontinuous mechanical problem successfully. The simulation of the process shows how different process parameters influence the thermo-mechanical response of the bars.

Residual stress formation mechanism considering cutting energy in milling of 7075 aluminum alloy

Residual stress formation mechanism considering cutting energy in milling of 7075 aluminum alloy

Improving fatigue initiation life of open-hole fibre metal laminates by laser shock peening

Although drilling open holes in fibre metal laminates reduces weight, it brings potential crack initiation sites. This paper investigates the effect of laser shock peening (LSP) on fatigue performance of open-hole titanium-based carbon-fibre/epoxy laminates (Ti-CF FMLs). A method based on multi-step simulation was proposed for the reconstruction of LSP induced residual stress field in open-hole Ti-CF FMLs. The results show that the fatigue initiation life of open-hole Ti-CF FMLs is improved by 22.1 %–81.0 % after LSP, depending on the structure of FMLs and the applied fatigue load. The improved fatigue crack initiation life attributes to compressive residual stress generated throughout the entire depth of the hole wall in outer titanium layer in Ti-CF FMLs after LSP. However, LSP leads to the formation of tensile residual stress far from the hole edge, resulting in accelerated propagation of fatigue crack. The fatigue initiation lives of open-hole Ti-CF FMLs before and after LSP were calculated by finite element simulation and theoretical method, showing good consistency.

Residual stresses and distortion in additively-manufactured SS316L-IN718 multi-material by laser-directed energy deposition: A validated numerical-statistical approach

In the present work, a numerical-statistical approach was used to study the distortion and residual stress in the additive manufacturing (AM) of SS316L-IN718 multi-material structure. Also, the structure was fabricated by laser-directed energy deposition (L-DED), and experimental measurements via thermocouple and micro X-ray diffraction were performed to validate the numerical results. In a good agreement with the experiments, the thermomechanical modeling of the process showed that through-thickness residual stresses (build direction) are distributed as a large accumulation of compressive residual stress in the mid-length of the structure-substrate interface and the maximum tensile residual stress at its two free ends. The critical development of longitudinal residual stresses (scanning direction) at the interface of the structure due to the sudden change in properties has caused the formation of the maximum tensile residual stress (up to 475 MPa) in this area and immediately changed its nature to compressive that can easily lead to localized cracking. Besides, Von Mises stress distribution indicated the concentration of stress at the interfaces of structure-substrate and base alloys, in such a way that it causes yielding in the SS316L section. On the contrary, less (plastic) strain occurred in the IN718 section due to higher yield strength. The results of the statistical modeling using multiple response analysis in the response surface method (RSM) also determined the desirable minimum level of longitudinal strain and stress of the structure (about 0.013 and 320 MPa, respectively) in the laser power range of 300–380 W and the powder per unit length of 5–25 g/m. In addition to minimization, it was demonstrated that sharp changes in longitudinal strain and stress at the interface of multi-material structure can be effectively reformed to mild changes by designing compositional gradients through thermodynamic calculations, owing to the approximation of the properties of adjacent layers.

Multiscale Process Modeling of Semicrystalline PEEK for Tailored Thermomechanical Properties.

Polyether ether ketone (PEEK) is a semicrystalline thermoplastic that is used in high-performance composites for a wide range of applications. Because the crystalline phase has a higher mass density than that of the amorphous phase, the evolution of the crystalline phase during high-temperature annealing processing steps results in the formation of residual stresses and laminate deformations, which can adversely affect the composite laminate performance. Multiscale process modeling, utilizing molecular dynamics, micromechanics, and phenomenological PEEK crystal kinetic laws, is used to predict the evolution of volumetric shrinkage, elastic properties, and thermal properties, as a function of crystalline phase evolution, and thus annealing time, in the 306-328 °C temperature range. The results indicate that lower annealing temperatures in this range result in a faster evolution of thermomechanical properties and shrinkage toward the pure crystalline values. Therefore, from the perspective of composite processing, it may be more advantageous to choose the higher annealing rates in this range to slow the volumetric shrinkage and allow PEEK stress relaxation mechanisms more time to relax internal residual stresses in PEEK composite laminates and structures.