Tensile Residual Stress Research Articles

Progressive Induction Hardening: Measurement and Alteration of Residual Stresses

Progressive induction hardening is an in-line steel heat treatment method commonly used to surface harden powertrain components. It produces a martensitic case layer with a sharp transition zone to the base material. This rapid process will induce large residual stresses, where a compressive state in the case layer will shift to a tensile state in the transition zone. For fatigue performance, it is important to quantify the magnitude and distribution of these stresses, and moreover how they depend on material and processing parameters. In this work, x-ray diffraction in combination with a layer removal method is used for efficient and robust quantification of the subsurface stress state, which combines electropolishing with either turning or milling. Characterization is done on C45E steel samples that were progressively induction hardened using either a fast or slow (27.5 or 5 mm/s, respectively) scanning speed. The results show that although the hardening procedures will meet arbitrary requirements on surface hardness, case depth and microstructure, the subsurface tensile stress peak magnitude is doubled when using a fast scanning speed. However, the near-surface compressive residual stresses are comparable. In addition, the subsurface tensile residual stress peak is compared with the on-surface tensile stresses in the fade-out zone.

Influence of GH4169 addition on cracking control, microstructure and mechanical properties of GH4169/K465 composite material manufactured by selective laser melting

In the process of additive manufacturing, K465 nickel-based superalloy tends to form a eutectic structure with a low melting point. Subsequently, rapid cooling leads to the formation of significant residual tensile stress. This tensile stress makes the prepared sample susceptible to cracking. The research explored the susceptibility to cracking of the alloy material and analyzed the microstructure and properties of GH4169/K465 alloy obtained. The generation of cracks can be managed by decreasing the concentration of Al and Ti elements. The microstructure of GH4169/K465 alloy consists of a matrix phase γ, a white Laves precipitated phase, and spherical particle precipitated phase NbTi4. The mechanical properties of samples 1GH1K, 7GH5K, and 3GH1K were analyzed. The results indicated an elongation exceeding 20 %, a tensile strength exceeding 1000 MPa, and a reduction in hardness from 329 HV to 285 HV. The powder mixing process has been demonstrated to effectively address the shortcomings of individual materials by combining the strengths of different alloy materials to produce a hybrid material with excellent comprehensive performance.

Acid resistance of hydroxyapatite dental films fabricated through powder jet deposition

This study proposes a novel dental treatment method using powder jet deposition (PJD). PJD can be employed to fabricate hydroxyapatite (HA) films directly on human enamel by blasting fine HA particles. Acid resistance tests were performed on HA films fabricated with two blast angles (α = 60° and 90° with two samples each) and using human enamel (with one sample) to evaluate the usefulness of the HA films in acidic intraoral environments. All samples were dissolved in acid, and their volume gradually decreased over the test time tacid. Transmission electron microscopy images showed that the grain boundaries near the acid-exposed surface of the HA films were densely modified and prevented acid penetration, whereas the human enamel grains became finer owing to the acid–base reaction. Thus, the HA films lost lesser volume than the human enamel did, indicating higher acid resistance. However, one film fabricated at α = 60° partially peeled off during tacid = 6–9 h. Analysis of the PJD phenomenon through smoothed particle hydrodynamics indicated that the tensile residual stresses promoting crack propagation and delamination increased as α became more acute, causing HA film peeling. Therefore, particles should be blasted in multiple directions to avoid stress bias.

Failure analysis of stress corrosion cracking in welded structures of aluminum alloy metro body traction beam in service

A comprehensive failure analysis was carried out for a crack appearing in the welded structure of an aluminum alloy body traction beam in a service metro vehicle. The fracture composition analysis reveals the products remaining after the reaction between the external corrosive medium and the material. A three-dimensional finite element model of the welded area of the traction beam was further established to simulate the high residual tensile stress present in the welded area. Based on the dynamic stress testing, it was found that the external loads had little effect on their crack growth. A series of analyses based on material properties, microstructure, fracture morphology and residual stresses identified stress corrosion as the leading cause of crack growth failure. Finally, a new structural repair program is proposed, and the reliability of the new structure in service life is verified by comparison, avoiding catastrophic fracture accidents in the service structure.

The Influence of Spray Cooling Parameters on Workpiece Residual Stress of Turning GH4169.

To effectively reduce residual stresses in GH4169 workpieces, thus enhancing fatigue strength and operational lifespan, this study investigates the influence of spray cooling parameters on surface residual stresses during GH4169 turning in spray cooling conditions, utilizing both simulation and experimental approaches. A simulation model of residual stresses was established using finite element analysis when GH4169 was cut in spray cooling. The effects of spray pressure and flow rate on residual tensile stresses were analyzed. The analysis reveals that with increasing spray pressure, residual tensile stresses show a decreasing trend, gradually stabilizing. Conversely, with an increasing spray flow rate, residual tensile stresses initially decrease and then increase. The turning experiments of GH4169 were conducted under different spray parameters. After the experiment, the workpiece was sectioned and analyzed for residual stresses using X-ray diffraction instrumentation. The value residual stress measured closely matched those of simulation, with a relative error within 6%, validating the accuracy of the simulation model and confirming the appropriateness of parameter settings. These results contribute to the further promotion of spray cooling technology and facilitate the rational selection of spray parameters.

Microstructure evolution, stress state and electromagnetic performance of Fe-based nanocrystalline alloy induced by stress-annealing

Stress-induced anisotropy has been applied for FeSiBCuNb nanocrystalline alloy ribbons in transformers with large direct current (DC) component. However, the physical mechanism of anisotropy induced by stress annealing during crystallization remains controversial. Here, a systematic study was conducted on the microstructure, residual stress state, dynamic domain structure and properties of the stress-annealed FeSiBCuNb nanocrystalline ribbons. Present results demonstrate that, the increase of the applied stress greatly increases the residual tensile stress and induces lattice distortion, which acts as pinning site during magnetization, resulting in enhanced domain-wall energy and narrower wall width. Meanwhile, stress annealing promotes the flattening of hysteresis loops and decreases the effective permeability, which improves the DC-bias characteristics of the ribbons, thereby promoting the transition from “hard saturation” to “soft saturation” behavior. Also, stress-induced grain refinement is beneficial to obtaining high hardness. Owing to the stress-induced anisotropy, the stress-annealed sample with applied stress of 113 MPa exhibits excellent combined properties, including low constant effective permeability of 438 at wide frequency range (1 kHz–8 MHz), high DC-bias capability of 74% (30 Oe), low power loss of 49 kW/m3 (100 mT, 100 kHz), and high hardness of 644 HV. This discovery provides an insightful understanding of stress-induced anisotropy mechanism on the high-performance Fe-based nanocrystalline alloys.

Effects of carbon-fibre Z-pins on the through-thickness tensile strength of curved composite laminates under four-point bending

This study investigates the influence of discrete through-thickness reinforcement, i.e. Z-pins, on the through-thickness tensile strength (TTS) of curved laminates through four-point bending experiments. Three types of samples are considered: unpinned, and Z-pinned with 0.27 % and 0.54 % areal densities. HexPly® IM7/8552 carbon/epoxy unidirectional prepreg with 0/±45 layup and 0.28 mm diameter T300/BMI pins were employed to manufacture the specimens. The Z-pinned laminates have comparable TTS with the unpinned samples in terms of the first observable load-drop. However, the TTS corresponding to the ultimate load-drop for low-density and high-density Z-pinned samples are 29 % and 38 % lower than for the unpinned ones, respectively. Z-pinned samples show less scatter than unpinned ones in terms of the ultimate TTS values. All specimens failed suddenly, i.e. with no evident damage progression. This implies that Z-pins were not able to form a progressive bridging zone to dissipate mechanical energy. Through a detailed meso-scale finite element analysis (FEA), it was found that the high through-thickness tensile residual stress in the Z-pin neighbourhood generated from the cool-down stage of cure is an important factor in causing the reduction in TTS of Z-pinned laminates. CT scan images of tested Z-pinned specimens show that the carbon-fibre pins experience fracture inside the laminates.

Backside metallization affects residual stress and bending strength of the recast layer in laser-diced Si

Thin Silicon dies separated by laser dicing form a thin layer via redeposition of ablated silicon known as recast layer. This work analyzed the influence of the recast layer microstructure and nanoscale residual stress gradients on the bending strength of bare and metalized silicon dies <100 μm. Scanning and transmission electron microscopy revealed an intricate microstructure of ablated silicon and elements of the wafer backside metallization within the recast layer. Refined silicon grains decorated by nanoscopic metallic precipitates at their grain boundaries were observed. Cross-sectional synchrotron X-ray nanodiffraction revealed that the altered microstructure increased the tensile residual stress from 200 to 295 MPa for bare and metalized dies, respectively. Additionally, the metalized die exhibited gradients in residual stress and grain size between the die front- and backside. Despite their similar frontside bending strengths of ∼340 MPa, observed in 3-point bending experiments, a considerable strengthening of the backside from 425 up to 957 MPa was measured for bare and metalized die, respectively. The origins of the tensile residual stress and the influence of the backside metallization on the die bending strength are discussed.

A gradient strengthening method of wire-arc additive manufacturing coupling with surface rolling and its application

The gradient distribution of properties, which satisfies the service requirements of critical components operating in extreme environments, plays a significant role in enhancing the durability of these components. Here, a new method of wire-arc additive manufacturing (WAAM) coupling with surface rolling was proposed to construct the gradient distributed properties. The present study focuses on a typical application of this method, wherein the surface of an exhaust valve in a marine diesel engine is processed to achieve a gradient property. The gradient strengthening mechanisms were investigated through numerical simulation and physical experiments. Simulation results demonstrated that the residual tensile stress resulting from WAAM was significantly reduced and mostly converted to compressive stress after surface rolling. The initial maximum residual tensile stress of 208.6 MPa, located at the surface of the deposited valve, was reduced to −167.8 MPa after surface rolling. The depth of residual compressive stress was extended 6–7 mm from the rolled surface to the deposited zone. Analysis of microstructures revealed that three distinct zones with different microstructural characteristics were generated through the proposed method, thereby forming the gradient microstructures. Specifically, the surface rolled zone was characterized as nanocrystallines (<1 μm), refined grains (1–10 μm), and deformed grains (>10 μm), while the deposited zone and substrate corresponded to columnar grains and equiaxed grains, respectively. A wide gradient strengthening layer with an approximate thickness of 8 mm was achieved on the processed valve surface, exhibiting a hardness gradient from 314 MPa at the substrate to 566 MPa on the rolled surface. The gradient strengthening mechanisms were attributed to intrinsic material strengthening, grain boundary strengthening and dislocation strengthening.

Experimental study on the ultrasonic assisted face turning residual stress

ABSTRACT The Experimental study investigates the impact of ultrasonic-assisted face turning (UAFT) on cutting forces, tensile residual stress, and surface topography. The primary objective is to identify optimal cutting parameters that yield a smoother surface finish while concurrently reducing cutting forces and tensile residual stress. The tests were conducted on a lathe machine equipped with ultrasonic assistance, using 1.7225 steel as the workpiece material. Various cutting parameters, including feed rate, spindle speed, and turning state, were varied. The results illuminate the significant efficacy of ultrasonic assisted face turn (UAFT) in improving surface topography, compared to conventional turning (CT). The optimal turning parameters for achieving the smoothest surface finish were determined to be a higher spindle speed and lower feed rate. Moreover, the introduction of ultrasonic vibration led to a substantial reduction in cutting forces, primarily attributable to the diminished attrition between the cutting tool insert and the work part. Overall, the experimental study demonstrates the effectiveness of ultrasonic-assisted face turning in enhancing surface topography, with an improvement of approximately 39%. Additionally, the study demonstrated a reduction in cutting forces by approximately 50% and a decrease in tensile residual stress by approximately 33.8%. These findings underscore the potential of ultrasonic vibration as a tool for optimizing cutting parameters to achieve desired surface finishes in machining applications.

Prediction of residual stress depth profiles in case-carburized gears

Residual stresses have a significant influence on the load carrying capacity of gears. High near-surface compressive residual stresses can increase pitting strength and tooth root bending strength up to 50%. Tooth flank fracture (TFF) is a gear fatigue failure mode, which is in contrast to pitting or tooth root breakage not initiated at the surface or close to the surface but in larger material depths beneath the active gear flank. Therefore, the residual stresses in larger material depths are decisive for TFF. In these larger material depths, the residual stress conditions are almost unknown up to now. It is assumed that tensile residual stresses are present in these areas, which can negatively influence the TFF load carrying capacity. So far, no validated methods are known to estimate or predict these tensile residual stresses. As a result, the tensile residual stresses could not be considered in the calculation methods for the risk of TFF at all until recently.This paper presents a method to predict the residual stresses in case-carburized gears based on comprehensive numerical simulations of case-carburizing processes of different-sized gears. The calculated residual stress profiles also consider the tensile residual stresses in larger material depths.

Fracture and electrochemical behavior of S355 steel welded joint under High-Frequency vibration

The influences of the high-frequency vibratory stress relief (VSR) on the surface residual stress, the impact toughness, the fracture morphology, the chemical composition, the microstructure, and the electrochemical corrosion resistance of S355 steel welded joints were analyzed. The improvement mechanism of the high-frequency vibration on the impact toughness and the electrochemical corrosion resistance were discussed. The SEM and EDS results indicated that the plasticity of the metal material was enhanced since the size and depth of the dimples in each region of the impact specimens were increased, the uniformity was better. In this case, the impact toughness of the S355 steel welded joints after the high-frequency VSR was improved. Moreover, the electrochemical corrosion resistance of the heat affected zone of the S355 steel welded joints was improved by the high-frequency VSR. Meanwhile, the grain size and the microstructure morphology of the S355 steel welded joints remained almost the same before and after the high-frequency VSR. The findings confirm that the reduced residual tensile stress could improve the impact toughness and the electrochemical corrosion resistance of the S355 steel welded joints.

Analysis of crack propagation of annular butt weld and distribution of weld-induced residual stress

The circumferential surface crack propagation and the effect of weld-induced residual stress were analyzed to comprehensively understand the mechanical behavior and fracture resistance of dissimilar girth welded joints of steel castings. The evaluation of stress intensity factors is conducted for circumferential cracks on internal surfaces, aiming to predict the fracture toughness of dissimilar welded joints. The distribution of weld-induced residual stress is obtained by thermal elastic-plastic finite element methods. The impact of residual stress on the propagation of cracks is investigated through the application of extended finite element theory. The high-stress intensity factors were found in such dissimilar welded joints due to the local bending and distortion caused by the asymmetrical weld geometry. The tensile residual stress and distortion were applied to the weld root area and its vicinity. Both the asymmetrical weld geometry and tensile residual stress contribute to the tensile distortion of the inner surface around the weld root, and enable the growth of internal surface cracks in the circumferential direction and radially from inside out of the welded joint. The fracture resistance decreases with the simultaneous influence of residual stress and welds’ asymmetry.

Investigating the effects of steel strength and tensile overload level on fatigue crack growth performance

Individual overloads (OLs) might significantly relax tensile residual stresses (RS) besides generating compressive RS in welded components and, thus, influence the fatigue performance of these components. This study seeks to investigate the effects of steel strength and OL level on the fatigue life performance of welded components. Welding calculations were first performed for different steel grades to predict welding RS (WRS). A series of numerical fatigue calculations were conducted using the elastic–plastic fracture mechanics approach based on FEM to comprehend the fatigue performance under various OL levels. The fatigue calculations were performed in the absence and presence of the WRS effect. The results showed that the higher-level OLs improved the fatigue performance of components made of higher-strength steel when the WRS effect was considered. In contrast, in the absence of the WRS effect, an improvement in fatigue performance was achieved from the higher-level OLs by lower-strength steel. Also, a remarkable RS relaxation with varying degrees was induced from the higher-level OLs for the applied steel grades. This variation in the degree of RS relaxation could be attributed to the difference in WRS distributions over the crack surface. The crack driving force and retardation effect were also used to support the study.

Microstructure regulation and performance of titanium alloy coating with Ni interlayer on the surface of mild steel by laser cladding

The preparation of Ti-alloy coating on the steel surface via laser cladding is very easy to form Fe-Ti phase and large tensile residual stress, which is not conducive to the performance of Ti-alloy coating. Here, Ti-6Al-4V coating (TC4-coating) was prepared on the mild steel substrate using laser cladding technology with Ni-alloy as the interlayer, and the Fe-Ti phase inside was completely suppressed. Increasing the powder feeding rate and scanning speed can change the undercooling of the alloy melt and the preferred growth orientation of the grains, while limiting the abnormal grain growth and grain boundary segregation, which is beneficial for grain refinement and equiaxed crystal formation. Reducing the scanning speed and powder feeding rate can increase the molten pool lifetime, thereby increasing the dilution rate of the coating and facilitating the formation of Ti2Ni phase. The abundant Ti2Ni inside the coating gives the TC4-coating greater microhardness (>500 HV0.1) and better corrosion resistance (Icorr of 7.00 × 10−8 A·cm−2). Grain refinement of the coating texture caused by the increase of powder feeding rate and scanning speed, as well as the high content of β-Ti phase and martensite structure, can improve the adhesion and shear strength of TC4-coating (386 ± 31 MPa).

Ultrasonic Non-Destructive Detection Method for Residual Stress in Rotary Forging Aluminum Alloy Plates.

Aluminum alloy plates are widely used to manufacture large-scale integral structure parts in the field of aerospace. During the forming and processing of aluminum alloy plates, different degrees of residual stress are inevitably produced. Fast and accurate detection of residual stress is very essential to ensuring the quality of these plates. In this work, the longitudinal critically refracted (LCR) wave detection method based on a one-transmitter and double-receiver (OTDR) transducer and the finite element simulation were employed to obtain the residual stress. Aluminum alloy plates with different deformation amounts were fabricated by rotary forging to obtain different residual stress states. Results reveal that the plate formed by rotary forging is in a stress state of central tension and edge compression. As the deformation increases from 20% to 60%, the peak residual tensile stress increases from 156 MPa to 262 MPa, and there is no significant difference in the peak compressive stress. When the deformation reaches 60%, the difference in the residual stresses at different depths is less than 13%, which indicates that the plastic deformation zone basically penetrates the entire longitudinal cross-section of the plate. The maximum deviation between measurement and FE is 61 MPa, which means the experimental data are in good agreement with the FE results.

Hydride orientation near pressure tube-end fitting rolled joints

The connection between Zr–2.5%Nb pressure tubes and modified martensitic stainless steel-403 end fittings in Pressurized Heavy Water Reactors (PHWRs) at the rolled joint is a critical site marked by enhanced hydrogen diffusion and elevated tensile residual stresses. The application of circumferential stress above a threshold leads to the formation of radial hydrides. Formation of radial hydride leads to a drastic reduction in fracture toughness and increase in Delayed Hydride Cracking (DHC) velocity. A comprehensive understanding of residual stress, hydride orientation and radial hydride fraction in this region is essential for the assessment of pressure tube structural integrity. In this study, we employ 3D nonlinear finite element analysis to estimate the residual stresses near rolled joints for both 220 MWe and 700 MWe pressure tubes. Additionally, we pioneer an experimental investigation into hydride orientation near roll joints through internal pressurization of hydrided pressure tube and end fitting assemblies. The study delves into the influence of residual stresses due to rolling process on hydride orientation and radial hydride fraction, providing crucial insights for the evaluation of the structural integrity of pressure tubes.

Analysis of lattice deformation originated from residual stress on performance of aluminum nitride-based bulk acoustic wave resonators

With the development of MEMS technology to the nanometer scale, the influence of different process conditions on the performance of nano-devices can be calculated through the microscopic changes of materials. During the manufacturing process, the large residual stress from the film stack significantly influences the performance of devices, thereby reducing the wafer yield. Herein, we apply density functional theory to MEMS processes to reveal the intrinsic mechanism of how residual stress affects the performance of aluminum nitride-based bulk acoustic wave (BAW) resonators on an 8-inch high-resistance silicon wafer. The variation rule of physical properties of piezoelectric material aluminum nitride with different residual stresses is calculated via first-principles calculations. Through theory formula derivation, the piezoelectric-coupling constant (Kt2) of the bulk acoustic wave resonator is positively correlated with tensile residual stress, and the resonant frequency (fp, fs) is negatively correlated with tensile residual stress. The measurement results show that the average shifts of Keff2 is 0.12 % within −137 MPa and 183 Mpa residual stress, which is an excellent match with the theory prediction.

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.

Residual stress variations in substrate (AISI D2) during directed energy deposition process of high-speed tool steel (AISI M4) powder

This study aims to observe the residual stress in a substrate and predict stress behavior during the laser deposition process (DED) using finite element analysis (FEA). The residual stress observed on the substrate surface indicated that stress variation during the deposition process increases with proximity to the deposition area, resulting in higher residual stress levels. Additionally, tensile residual stress tends to increase with the height of the deposition area. While variations in the deposition area size influenced the residual stress, consistent stress levels were observed at the same measurement points across different area sizes. The deposition process was simulated using FEA, which confirmed that stress behavior is influenced by melting and solidification cycles. The residual stress levels after cooling aligned well with those observed in actual experiments. Therefore, this study suggests that stress variations can be effectively predicted by simulating the deposition process prior to conducting actual experiments.