Formation Of Residual Stresses Research Articles

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.

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

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.

EXPERIMENTAL STUDY THE MECHANICAL PROPERTIES OF GMAW WELDING RESULTS ON S355J2+N MATERIAL WITH POST WELD HEAT TREATMENT (PWHT)

Assembly underframe trains are a connecting process part-part into a system that has a unified function, the process of which uses GMAW-type welding. From the welding results, there is potential for the formation of residual stress which is a problem in this research, so it is minimized using the method Post Weld Heat Treatment (PWHT) thermal. The research aims to determine and analyze the effect of PWHT on the mechanical properties and microstructure of low-carbon steel type S355J2+N resulting from GMAW welding. The research method uses experiments with PWHT temperatures at 450 °C, 750 °C, and non-PWHT to find out the mechanical properties of materials, use the tensile test and micro-Vickers hardness test. Meanwhile, to determine the microstructure formed is used micro examination. The test results, were compared between the welding material with PWHT and the welding material non-PWHT. The results of the research are that the largest tensile strength value of 576 MPa was produced in the material using PWHT at a temperature of 450 °C, the largest elongation of 34.85% was produced in the material with a PWHT temperature of 750 °C, and the highest hardness value was 207.44 HV in the material non-PWHT. The conclusion of the research shows that with increasing PWHT temperature, the hardness and tensile strength values of the material decrease, and there is an increase in the ductility value of the material which is influenced by changes in the dominance of ferrite and pearlite in the material.

Influence of absorptivity variation on Laser Powder Bed Fusion simulation and impact of process parameters on residual stress formation

Laser powder bed fusion stands out for its precision and capability to manufacture parts with complex geometry, yet it poses challenges due to the significant thermal gradient, causing elevated residual stress and potential damage. Ensuring precise manufacturing of Ti6Al4V, demands control over input parameters. This study employs a simulation model using COMSOL Multiphysics to explore the influence of thermal absorptivity on reliability of predicted results and role of key process parameters including laser velocity and power on temperature distribution and thermal stress. Results indicate that the volumetric heat source with temperature-dependent absorptivity, ended in more accurate predictions compared to constant absorptivity. Moreover, considering absorptivity as a function of laser power and velocity enhanced results particularly in situations with higher energy densities. However, while reducing the laser velocity and increasing laser power typically led to higher residual stress as the area exposed to high temperature was wider, there was a critical point for the impact of laser velocity, where the role of thermal gradient overcomes the role of maximum temperature.

Modeling the thermo-mechanical response and phase changes in metallic additive manufacturing (MAM) processes using a dissipative phase-field model

Additive manufacturing (AM) has emerged as a highly promising manufacturing technique, offering unprecedented possibilities for creating complex geometries and functional structures. However, harnessing the full potential of AM requires the development of a robust computational framework capable of capturing the intricate multi-scale and multi-physics nature of the process. The constitutive and structural responses encountered in AM are particularly challenging to reproduce due to the complex behavior of the material involved. This research aims to address these challenges by presenting a comprehensive computational approach that incorporates a material model capable of accurately representing the behavior of different phases occurring during AM. To achieve this, the finite element method, using the Lagrangian framework in the implicit time scheme, is employed through the widely adopted ABAQUS software. Computational implementation is facilitated using the FORTRAN programming language. By employing weakly coupled thermal and mechanical constitutive equations, the framework enables the analysis of thermal stresses, strains, and displacements during realistic solidification processes, which inherently involve highly nonlinear constitutive relations. Through a series of numerical examples, the capabilities of the proposed model are demonstrated across various computational scales, particularly during the rapid melting and solidification phases. These simulations reveal the formation of residual stresses, which can lead to part distortion and have detrimental effects on the mechanical properties of the manufactured components. This research contributes to the advancement of additive manufacturing by providing a reliable computational tool that integrates the complex interplay between thermal and mechanical phenomena. The developed framework enhances our understanding of the AM process, offering valuable insights into the factors influencing the structural integrity and performance of additively manufactured parts.

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.

Analysis of flatness and critical crown of hot-rolled strip based on thermal–mechanical coupled residual stress analytical model

Residual stress is introduced during hot-rolled strip production due to various factors, such as temperature distribution, crown change, and metal transverse flow. Excessive residual stress can cause flatness defects in the strip, while insufficient residual stress may result in deformation during subsequent cutting. To explore the mechanism of residual stress formation in hot-rolled strip and how to control it, an analytical model for the coupling of temperature, crown and residual stress is established. Firstly, based on the symplectic space Hamiltonian system, an analytical solution for the strip cross section temperature field in each inter-stand zone is obtained. Then the residual stress analytical model is derived based on the fiber rod model combined with the law of volume invariance, lateral metal flow function and high temperature stress relaxation phenomenon. Meanwhile, to verify the accuracy of the analytical model, a multi field coupled finite element model based on the measured data validation is established. The calculation results of the analytical model are in good agreement with the finite element model. Furthermore, the buckling model of strip in symplectic space Hamiltonian system is derived, and the critical buckling stress of different strip flatness defects is directly calculated. Finally, the residual stress analytical model is combined with critical buckling stress to calculate the critical exit crown ratio to keep the strip flat.

Residual stresses in thick composites considering through-thickness temperature gradients during manufacturing

In the composite materials of wind turbine rotor blades, residual stresses form during manufacturing due to the different thermo-chemo-mechanical behaviors of the fibers and the matrix. These residual stresses decrease the ultimate and fatigue strength of the blade because the failure stress and cycles to failure are reached at lower levels of external loading. It is thus of utmost importance to consider residual stresses in the design stage to obtain reliable blade designs.This work deals with the prediction of residual stresses in a thick composite representative for a spar cap in a wind turbine rotor blade. A model is formulated for the thermo-chemo-mechanically coupled problem. An emphasis is given on the non-uniform and time-variable temperature distribution across the thickness of the composite. The different sources of residual stresses (e.g., chemical shrinkage, non-uniform distribution of different thermal expansion coefficients of fibers and matrix, exotherm, etc.) are analyzed, quantified, and compared. The impact of the time-dependent temperature distribution on the formation of residual stresses is highlighted by means of a representative numerical example.