Stress In Steel Research Articles

Hot deformation behaviors and microstructure characteristics of Cr–Mo–Ni–V steel with a banded structure

Abstract On a Gleeble-3800 thermal simulator, the hot deformation behavior of Cr–Mo–Ni–V steel was studied, with the designed deformation temperature varying from 900 to 1,200°C and the strain rate in the range of 0.01–10 s−1. It was observed that as the strain rate was increased and the hot working temperature was reduced, the flow stress of the experimental steel increased. The study also evaluated the safe parameters for deformation of the Cr–Mo–Ni–V steel in the hot working process, based on the established processing maps. It was found that the deformation temperature window varying from 1,050 to 1,150°C and the reasonable strain rate in the range of 0.01–1 s−1 are beneficial to the hot deformation of the steel. In this research, the effect of processing parameters of the hot working process on the microstructure evolution of the banded structure was also investigated. According to the research result, the banded structure in the steel remained visible under the conditions of a strain rate of 10 s−1 and the hot working temperature in the range of 900–1,200°C. However, it should be noted that the banded structure in the steel then gradually disappeared when the hot working temperature was increased to 1,200°C.

Local relaxation of residual stress in high-strength steel welded joints treated by HFMI

This research studies the influence of high-peak loads on local relaxation of residual stress and fatigue damage in high-strength steel welded joints treated by high-frequency mechanical impact (HFMI) treatment. The joint behavior is simulated with elastic–plastic finite element analyses that account for the combined effect of geometry, residual stress, and material properties. This simulation uses two treated geometry models: with or without surface roughness on HFMI groove, and two material properties: S690QL and AH36 structural steels. The results show that surface roughness and load history, including high-peak loads, significantly influence fatigue response. It is revealed that the model neglecting the surface roughness cannot represent the amount of residual stress change and fatigue damage at less than 100 µm depth from the surface. In addition, the local yield strength in the HFMI-treated zone affects the plasticity behavior near the surface imperfection under the high-peak loads, which provides comparatively different fatigue damage between S690QL and AH36 in some cases. As a result, this study provides the further understanding needed to develop a robust modeling approach to the fatigue life estimation of HFMI-treated welds subjected to high-peak loads.

Effect of aspect ratio on the metal flow behaviour during forming process: A numerical simulation approach

This paper presents results on the effect of aspect ratio on the flow stress of 42CrMo4 steel using Deform™ 3D Version 11 simulation software. The FEM simulation process conditions were upsetting temperature of 1000 °C and 10 s⁻¹ strain rate. The sample aspect ratios (height/diameter) varied within commonly used ranges during conventional Gleeble experimentations. The aspect ratio did not affect the flow stress behaviour during forming. Generally, the forming conditions influence the flow stress-strain field and distribution behaviour, causing inhomogeneous deformation. A negligible effect of aspect ratio on typical industrial forging process is only attainable between 1.0 and 2.0. The implications of the results for industrial forging are elucidated.

Effect of Cryogenic Heat Treatment on Multiple Tempered D-2 Tool Steel

The present day scenario in the manufacturing sector demands high productivity and the life of cutting tools plays a major role in increasing productivity. The freezing of metals has been acknowledged, for many decades, as an effective method for increasing" wear life" and decreasing residual stress in tool steels. Wear test using pin-on-disc machine was used to investigate the effect of multiple tempering after cryogenic treatment of D-2 tool steel. Conventional quenching (1010◦C) and tempering (515◦C) treatments were given along with intermediate cryogenic treatment (−196◦C). Specimens were subjected to wear tests on pin-on-disc machine in dry sliding condition for sliding distance of 6000 m at 6 kg load and for sliding speed of 3.0 m/s. Hardness data, microstructures, wear loss and Microstructure analys is analysis of worn surface throw light on the underlying metallurgical mechanism responsible in improving wear resistance property of the D-2 tool steel

Experimental and Numerical Study of Membrane Residual Stress in Q690 High-Strength Steel Welded Box Section Compressed Member.

High-strength steel (HSS) members with welded sections exhibit a notably lower residual compressive stress ratio compared with common mild steel (CMS) members. Despite this difference, current codes often generalize the findings from CMS members to HSS members, and the previous unified residual stress models are generally conservative. This study focuses on the membrane residual stress distribution in Q690 steel welded box sections. By leveraging experimental results, the influence of section sizes and welding parameters on membrane residual stress was delved into. A larger plate size correlates with a decrease in the residual compressive stress across the section, with a more pronounced reduction observed in adjacent plates. Additionally, augmenting the number of welding passes tends to diminish residual stresses across the section. Results showed that membrane residual stress adhered to the section's self-equilibrium, while the self-equilibrium in the plates was not a uniform pattern. A reliable residual stress simulation method for Q690 steel welded box sections was established using a three-dimensional thermal-elastic-plastic finite element model (3DTEFEM) grounded in experimental data. This method served as the cornerstone for parameter analysis in this study and set the stage for subsequent research. As a result, an accurate unified residual stress model for Q690 steel welded box sections was derived.

Analysis-oriented stress-strain model for concrete in steel tubed geopolymer concrete (STGC) columns

To alleviate the brittleness of geopolymer concrete and further promote its engineering application for environmental benefits, a novel type of column, i.e., steel tubed geopolymer concrete (STGC) column, has been proposed recently. Note that an accurate axial stress-strain model is necessary for a comprehensive understanding of the compressive behavior of STGC columns. However, the existing analysis-oriented models are all developed for the conventional concrete-filled steel tube (CFST) columns, and the confinement mechanism of steel tubed concrete columns is significantly different from that of concrete-filled steel tube columns since the axial deformation of steel tube and core concrete is not synchronized for steel tubed concrete columns during the loading process due to the discontinuous steel tube. Furthermore, the dilation properties of STGC columns at the initial loading are significantly overestimated by the existing lateral-axial strain models. Besides, steel-confined geopolymer concrete (GPC) experiences a more remarkable softening behavior resulting from the more significant brittleness of GPC than that of ordinary concrete. Thus, the deformation models are proposed in this study and the active-confinement base model is also developed for GPC based on the mechanical characteristics of STGC columns under axial compression. Then a new analysis-oriented model is proposed for steel tubed geopolymer concrete. Comparisons between the theoretical calculations and the test results indicate that the proposed model can provide reasonable predictions for both steel stress evolution and the stress-strain relationship of STGC.

Effect of annealing process on microstructure, residual stress, and fatigue behaviour of AISI 2205 duplex stainless steel

ABSTRACT This study investigated the microstructure, residual stress, and fatigue behavior of duplex stainless steels that have been annealed with different annealing processes. A cold-rolled AISI 2205 Duplex Stainless Steel (DSS) sample was annealed in three ways for this purpose. In modes 1 and 2, samples were annealed at 500°C for 6 and 8 hours, respectively. The sample was annealed for 6 hours at 950°C for mode 3.The Optical Microscopy (OM) technique was used to determine the crystallographic texture and microstructural characteristics. An X-ray Diffraction (XRD) analysis was used to determine the residual stresses in austenite and ferrite phases on pre- and post-heat-treated samples. The Scanning Electron Microscope (SEM) technique was utilized to assess fatigue cracks. The results showed that the texture microstructure of the specimens using mode 1 and 2 were remained; the grain had a smaller fragmentation. The elongation grains of the specimen after mode 3 were smaller, relatively spheroidal, and more homogeneous. There was a reduction in residual stress after mode 3 annealing process. The fatigue strength of the specimens that under applied this process was 11.1% higher than that of specimens in the as-received state.

Influence of Surface Mechanical Attrition Treatment Parameters on the Residual Stress of EN8 Steel

Influence of Surface Mechanical Attrition Treatment Parameters on the Residual Stress of EN8 Steel

Bearing Characteristics with Effect of Bond–Slip Behavior in Massive Ring-Type Reinforced Concrete Structures

The bond–slip behavior of the steel–concrete interface is critical in reinforced concrete (RC) structures since the bond action is the mechanism that ensures the two materials work in co-operation. However, there is little research considering the bond–slip behavior in massive ring-type reinforced concrete (MRRC) structure bearing analyses due to the complexity of modeling the interfacial behavior. Hence, the influence of the bond–slip behavior on the bearing characteristics of MRRC structures remains unclear. Steel-lined reinforced concrete penstock is such an MRRC structure, composed of steel liner and reinforced concrete and commonly used in diversion pipelines. This paper aims to explore the bearing characteristics considering the bond–slip behavior in the composite penstock by using a promising numerical method, the cohesive zone model. Three interface models were proposed to represent the different interaction conditions at the steel–concrete interface. Moreover, a sensitivity analysis was performed to study the impact of the bond strength on the bond performance and structural behavior. The simulation results showed that the prediction results (steel stress and crack process) considering the bond–slip behavior were in good agreement with the experimental results. The steel stresses near the cracks were smaller and more uniform after considering the bond–slip behavior, since the stresses were no longer concentrated on the crack but distributed in an area near the crack. However, the steel stress differences in these models were within 10%, which means that the bond performance had a limited effect on the structural safety design. The crack widths were greatly influenced by the bond conditions, and the maximum crack width (0.461 mm) in poor conditions was beyond the limiting value (0.3 mm). Consequently, bond–slip behavior must be paid more attention in durability design.

Intervention mechanism of carbide precipitation during tempering and its impact on residual stress and mechanical properties of wear-resistant steels

The production of low-stress, high-performance wear-resistant steels poses a formidable challenge in the steel industry. This article delves into the carbide precipitation behaviour of wear-resistant steel NM300TP during tempering and its subsequent impact on residual stress and mechanical properties. Our findings reveal a crucial aspect: prolonging the holding time can interfere with the precipitation behaviour of carbides, thereby altering the relaxation mechanism of residual stress and its influence on material properties. Remarkably, we discovered that substituting the formation of θ-cementites with the precipitation of ε-transition carbides can yield a steel with significantly lower residual stress while maintaining exceptional mechanical properties. Specifically, when θ-cementites precipitate, the residual stress in the wear-resistant steel diminishes by 54.23%, accompanied by a hardness measurement of 299.58 HV0.5. However, when a substantial quantity of ε-transition carbides is dispersed and precipitated, the residual stress is further diminished by 69.51%, and the hardness reaches 317.2 HV0.5. Furthermore, this precipitation of ε-transition carbides exhibits superior wear resistance compared to θ-cementites. These groundbreaking discoveries offer critical theoretical insights for the development of low-stress, high-performance wear-resistant steels, paving the way for innovative advancements in the steel industry.

Comparison of the effects of induction heating composite shot peening and conventional shot peening on residual stress, microhardness, and microstructure of 20CrMnTi gear steel

As a commonly used surface strengthening technology, shot peening, which can significantly improve the fatigue strength of mechanical parts, is widely used in the fields of vehicles and aviation. To obtain a larger residual compressive stress and further refine the grain size under normal shot peening intensity and coverage, this study proposes an induction heating composite shot peening (IHCSP) surface strengthening method, aiming to utilize the coupling effect of temperature and stress fields to promote the shot peening strengthening effect. An IHCSP test plan was designed and an IHCSP test bench was created to achieve simultaneous induction heating and shot peening. This study compares the surface integrity parameters and microstructures under three processes: un-peened, conventional shot peening, and IHCSP. The results show that the maximum axial and radial compressive residual stresses increase by 72.41 and 75.4 MPa respectively; the depth of the hardened layer increases by 0.3 mm, the martensitic transformation more complete, the grain size decreases by 483 nm, the dislocation density increases significantly, and nanocrystals are obtained on the surface of the material. These results verify the superiority of IHCSP surface strengthening.

Deep learning-based prediction of thermal residual stress and melt pool characteristics in laser-irradiated carbon steel

Residual stress is a crucial factor that must be managed in laser manufacturing processes. Neglecting it can result in product failure or unsuitability for the intended use. In this article, we present the first surrogate deep learning model based on generative adversarial network that predicts thermal residual stress and melt pool characteristics on the cross-section of laser-irradiated carbon steel. The model was trained using simulation data obtained from the unified momentum equation approach-based numerical model. Our model was designed to predict various aspects of the laser melting process only from three scalar inputs of laser power, beam diameter, and irradiation time at two different points in time (immediately after the laser heating is finished and when the steel is completely cooled down) and successfully predicted the distributions of 12 variables, including residual stress and temperature. Prediction results were not only qualitatively very similar to their ground truth, but also quantitatively accurate with the R2 values ranging from 0.975 to 0.999 and the mean absolute errors between 0.0015 and 0.0126. We demonstrated that complex experiments can be quickly performed using the surrogate model because a single deep learning prediction took only 0.13 s, compared to the 2.5–8 h numerical simulation times.

Experiment and mechanism investigation on the effect of deep cryogenic treatment on residual stress and machining deformation of hydrogen-resistant steel

Hydrogen resistant steel is widely used in various fields due to its numerous advantages, including high strength, toughness and excellent corrosion resistance. However, the presence of initial residual stress in the material is a significant factor contributing to machining deformation. To mitigate this problem, the contour method was used to determine the initial residual stress for various aging parameters. As a result, a set of optimal cryogenic treatment parameters (350 °C 2 h, −130 °C 10 h, 350 °C 2 h) was proposed to effectively reduce the initial residual stress. The results showed that under the optimal cryogenic treatment parameters, the residual stress reduction effect was most significant, with a value of 189 MPa. Compared to no aging treatment, the residual stress was reduced by 54.2 %. The effect of deep cryogenic treatment on the microstructure of hydrogen resistant steel materials was investigated by TEM. Compared to no aging treatment, the average dislocation density decreased by 51.5 % after treatment with the optimal cryogenic treatment parameter. In addition, the lattice spacing was reduced to 0.246 nm after deep cryogenic treatment, and two types of carbides were precipitated, i.e., spherical carbides (with a diameter of 24 nm) and rod carbides (with a length of 15 nm). The changes in grain size of the material after deep cryogenic treatment were further investigated by EBSD. The number of grains increased by 38.5 % after cryogenic treatment compared to no treatment. In addition, it was verified by non-contact material removal experiments that deep cryogenic treatment could reduce the machining distortion of thin-walled parts. Finally, for thin-walled parts used in engineering, a deep cryogenic treatment was interspersed during machining, resulting in a significant reduction in the overall deformation of the workpiece.

Structural impact under accidental LNG release on the LNG bunkering ship: Implementation of advanced cryogenic risk analysis

The potential risk associated with the accidental release of Liquefied Natural Gas (LNG) is a notable concern during the design phase of gas-handling facilities. One of the risk is an excessive cryogenic exposure to structures or equipment, leading to hazardous situations. This study aims to introduce a novel method that implements Advanced Cryogenic Risk Analysis (ACRA) to enhance the safety of LNG bunkering ship structure in case of cryogenic flow leakage. The method involves evaluating thermal loads based on the preceding simulated LNG release scenarios using Computational Fluid Dynamics (CFD). These thermal parameters are then employed in structural analysis through the Finite Element (FE) approach.The integration of thermal data from CFD simulations into the FE model was achieved using the Random Forest algorithm. The LNG bunkering structure is represented using DH36-grade steel material. Furthermore, to accurately capture the mechanical properties of DH36 steel, cryogenic tensile tests were conducted across a temperature range from 298.15 K to 113.15 K. The resulting stress-strain data from these tests were utilized to establish a reliable material model for conducting FE analysis.This paper comprehensively presents a novel ACRA procedure by utilizing physical parameter of the gas release cosnequence such as the steel temperature profile to identify the brittle failure under the accidental gas release on the LNG bunkering ship. In addition, quantitative risk analysis (QRA) was also presented regarding the cryogenic spill hazard, to link the probability and consequence aspects of the LNG bunkering risk, particularly the results of steel temperature, stress, and strain experienced by the ship’s structure. Furthermore, the individual risk was also estimated. The implications of the findings are discussed in detail regarding the cryogenic risk, cryogenic tensile test and numerical analyses.

Plastic anisotropy in yield stress of drawn pearlitic steels

Plastic anisotropy in the yield stress of pearlitic steels evolved by drawing was studied. The tension and compression tests were performed in parallel and perpendicular directions to the drawing direction. The yield stress in the parallel tension and vertical compression tests increased with the increase in drawing strain. On the other hand, in the parallel compression, the yield stress decreased significantly at the small drawing strain and then increased at the larger strain. The difference between the yield stress at the tension and at the compression did not change largely after the start of the drawing. The observation of microstructure indicated no significant heterogeneity of the deformation microstructure and texture at the different locations in the radial direction of the drawn samples, meaning that the plastic anisotropy was brought by reasons other than the non-uniformity of the deformation condition. The measurement of the distribution of the local misorientation in ferrite suggested the large plastic deformation even at smaller strain by drawing. This result indicates that the residual stress in plastically deformed ferrite brings back stress, which can be the source of the plastic anisotropy.

Identifying the influence of split tensile strength to crack width of high-strength reinforced concrete beam with polypropylene fiber from medical mask waste

Cracks in concrete structures due to tensile weakness can be repaired by using fiber concrete, including medical mask waste as an additive in high-strength concrete mixes. This research the influence of polypropylene fiber from medical mask waste on the mechanical characteristics, flexural behavior, and crack width of high-strength reinforced concrete (RC) beams. The initial stage involved examining the properties of the concrete constituent materials. The testing process was based on a high-strength concrete mix design using the Aitchin method mix design sheet. Compressive strength and split tensile strength were tested at fiber content (0 %, 0.15 %, 0.20 %, and 0.25 %). The three-point flexural testing procedure was carried out at 28 days on 1200×100×150 (mm) RC beams. The use of LVDT, strain gauge, and other measuring devices supported the acquisition of the required data. The results showed that the split tensile strength reached the optimum value of 66.19 MPa at 0.24 % fiber content. Polypropylene fiber from medical mask waste in RC beams showed a positive impact on reducing crack width at increased split tensile strength. Waste mask fiber content of 0.15 %, 0.20 % and 0.25 % gave stable and better results compared to 0 % content (no fiber). With high steel stress (fs), and high strain, it offers the potential to improve the mechanical properties of high-strength concrete, thereby reducing the width of cracks that occur. This improves the tensile weakness of the concrete. The effect of split tensile strength on the crack width (w) of beams with the formula approach: wexp=3.74ftf-1.513, wan=0.187ftf-0.022 shows that the experimental results have a significant effect on decreasing the crack width that occurs in high-strength RC beams, thereby improving the quality of concrete

Effect of Different Microstructures on Surface Residual Stress of Induction-Hardened Bearing Steel

JIS SUJ2 steel is most widely used in bearing steel. The advantages are good hardenability, excellent fatigue, wear resistance and comprehensive mechanical properties. The wear resistance and fatigue resistance of this steel are attracting more attention, and the residual stress state and its distribution on the surface of the heat affected zone are critical factors affecting the fatigue life and wear resistance of the parts. In this study, SUJ2 is used as a material by which to study the surface residual stress and retained austenite distribution of induction-hardened steel. Quenching and tempering treatments were used to obtain different microstructures and an induction method was used to re-quench the case region. After the heat treatment, the residual stress and retained austenite volume on the surface were analyzed by X-ray diffraction and analyses of the microstructure and the hardness were also conducted. The results show that the microstructure after heat treatment contains unsolved carbides, tempered martensite and retained austenite. In the induction-hardened area, the residual stress is all compressive, and the values are more than −750 MPa. In conclusion, the microstructures of the specimens before induction hardening have a significant impact on the effective case depth for the same output power condition and the surface residual stress changes from a tensile to a compressive state. In the induction-hardened area, the maximum of the residual compressive stress was increased as the austenitized temperature of quenching increased.

Revisiting the universality law in magnetically detected residual stresses in steels

The dependence of residual stresses on differential permeability, determining the so called Magnetic Stress Calibration (MASC) curve, results in the Universal MASC curve after normalizing the stress and permeability axes with the yield stress and the maximum differential permeability of the steel under test, respectively. The motivation of this paper is to illustrate the ability of obtaining the MASC curve of an unknown steel just by measuring its yield stress and maximum differential permeability. The calculated MASC curve of an unknown type of steel, obtained by multiplying the stress and permeability axes of the Universal MASC curve with the yield stress and maximum differential permeability obtained by the stress-strain curve under simultaneous measurement of the permeability, was compared with the actual MASC curve of the same unknown type of steel determined by the classical method, with an agreement better than ±5%. The conclusion is that the actual MASC curve of an unknown type of steel can be determined just by a stress-strain measurement, with simultaneous determination of the maximum amplitude of the differential permeability.

Probabilistic model for cracking localization in reinforced fibrous concrete beams

This paper proposes a probabilistic model that explains the phenomenon of cracking localization (CL) in RC beams with addition of steel fibers. Quantification of the CL is defined as the ratio between the total number of cracks and the number of significantly wide cracks. The model considers both the fibers and conventional reinforcement ratios, as well as the steel stress hardening and the location of the rebars in the cross-section. The fiber distribution in the concrete mix is considered random while the conventional reinforcement—as deterministic. A cumulative function of the total steel distribution, and a binomial probability function are proposed for a newly defined variable that represents the distribution of the fibers effectiveness along the beam. The model was validated with available data from flexural experiments showing good agreement of the model’s prediction with the reported results. The model shows that the cracking localization level in beams is more pronounced in beams with low reinforcement ratios and relatively large fibers content and enables its quantification.

Experimental investigation and predictive models of membrane residual stresses in S690 high strength steel welded π-shaped and cruciform sections

This paper reports an experimental investigation of the membrane residual stresses in S690 high strength steel welded π-shaped and cruciform sections. The experimental programme was performed on three π-shaped sections and two cruciform sections, fabricated from 5 mm thick S700MC high strength steel plates by means of gas metal arc welding, and included material tensile coupon tests and membrane residual stress measurements, with two measurements for each of the five S690 high strength steel welded π-shaped and cruciform sections. The measured tensile and compressive membrane residual stresses were analysed and the self-equilibrium of the measured membrane residual stresses in each constituent plate element was also verified, with the maximum unbalanced membrane residual stress to yield stress ratios of 3.3% for π-shaped sections and 3.2% for cruciform sections. The existing membrane residual stress predictive models, as given in the European convention and Swedish regulations, were assessed for their applicability to S690 high strength steel welded π-shaped and cruciform sections, revealing inaccuracy. Finally, two sets of new predictive models for membrane residual stresses in S690 high strength steel welded π-shaped and cruciform sections were proposed and shown to result in accurate predictions of the measured membrane residual stress data.