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Sample records for measured residual stresses

  1. Electromechanical Apparatus Measures Residual Stress

    NASA Technical Reports Server (NTRS)

    Chern, Engmin J.; Flom, Yury

    1993-01-01

    Nondestructive test exploits relationship between stress and eddy-current-probe resistance. Yields data on residual stress or strain in metal tension/compression specimen (stress or strain remaining in specimen when no stress applied from without). Apparatus is assembly of commercial equipment: tension-or-compression testing machine, eddy-current probe, impedance gain-and-phase analyzer measuring impedance of probe coil, and desktop computer, which controls other equipment and processes data received from impedance gain-and-phase analyzer.

  2. Electromechanical Apparatus Measures Residual Stress

    NASA Technical Reports Server (NTRS)

    Chern, Engmin J.; Flom, Yury

    1993-01-01

    Nondestructive test exploits relationship between stress and eddy-current-probe resistance. Yields data on residual stress or strain in metal tension/compression specimen (stress or strain remaining in specimen when no stress applied from without). Apparatus is assembly of commercial equipment: tension-or-compression testing machine, eddy-current probe, impedance gain-and-phase analyzer measuring impedance of probe coil, and desktop computer, which controls other equipment and processes data received from impedance gain-and-phase analyzer.

  3. Ultrasonics used to measure residual stress

    NASA Technical Reports Server (NTRS)

    1967-01-01

    Ultrasonic method is used to measure residual stress in metal structures. By using this method, various forms of wave propagation in metals are possible, and more thorough analysis of complex geometric structures may be had.

  4. Measuring Residual Stress Using Nonlinear Ultrasound

    NASA Astrophysics Data System (ADS)

    Liu, M.; Kim, J.-Y.; Qu, J.; Jacobs, L. J.

    2010-02-01

    Near-surface compressive residual stresses, which are generated by shot peening, are known to retard crack initiation and thus extend the fatigue life of a metal component. The ability to effectively measure these near-surface residual stresses would greatly help predict the fatigue life of shot-peened components. This research uses the nonlinear surface acoustic wave technique to measure the residual stresses in a shot-peened component. Experiments are conducted on three different aluminum alloy (AA 7075) samples: as-received with no peeing, and shot-peened at the Almen intensities of 8A and 16A. Surface roughness measurements are also carried out for these three samples. The nonlinear ultrasonic results show that the measured acoustic nonlinearity parameter increases by 81% and 115% for the 8A and 16A samples. These large increases in measured acoustic nonlinearity clearly indicate the potential of the nonlinear ultrasonic technique as an NDE tool to measure the near-surface residual stresses. The effects of surface roughness on the ultrasonic measurement are briefly examined. Finally, a preliminary model prediction is presented to interpret the experimental results.

  5. System and method for measuring residual stress

    DOEpatents

    Prime, Michael B.

    2002-01-01

    The present invention is a method and system for determining the residual stress within an elastic object. In the method, an elastic object is cut along a path having a known configuration. The cut creates a portion of the object having a new free surface. The free surface then deforms to a contour which is different from the path. Next, the contour is measured to determine how much deformation has occurred across the new free surface. Points defining the contour are collected in an empirical data set. The portion of the object is then modeled in a computer simulator. The points in the empirical data set are entered into the computer simulator. The computer simulator then calculates the residual stress along the path which caused the points within the object to move to the positions measured in the empirical data set. The calculated residual stress is then presented in a useful format to an analyst.

  6. Residual stress measurements in carbon steel

    NASA Technical Reports Server (NTRS)

    Heyman, J. S.; Min, N.

    1986-01-01

    External dc magnetic field-induced changes in natural velocity of Rayleigh surface waves were measured in steel specimens under various stress conditions. The low field slopes of curves representing the fractional changes of natural velocity were proved to provide correct stress information in steels with different metallurgical properties. The slopes of curves under uniaxial compression, exceeding about one third of the yield stress, fell below zero in all the specimens when magnetized along the stress axis. The slopes under tension varied among different steels but remained positive in any circumstances. The stress effect was observed for both applied and residual stress. A physical interpretation of these results is given based on the stress-induced domain structure changes and the delta epsilon effect. Most importantly, it is found that the influence of detailed metallurgical properties cause only secondary effects on the obtained stress information.

  7. Measurment Of Residual Stress In Ferromagnetic Materials

    NASA Technical Reports Server (NTRS)

    Namkung, Min; Yost, William T.; Kushnick, Peter W.; Grainger, John L.

    1992-01-01

    Magnetoacoustic (MAC) and magnetoacoustic emission (MAE) techniques combined to provide complete characterization of residual stresses in ferromagnetic structural materials. Combination of MAC and MAE techniques makes it possible to characterize residual tension and compression without being limited by surface conditions and unavailability of calibration standards. Significant in field of characterization of materials as well as detection of fatigue failure.

  8. Measurement of residual stresses using fracture mechanics weight functions

    SciTech Connect

    Fan, Y.

    2000-10-01

    A residual stress measurement method has been developed to quantify through-the-thickness residual stresses. Accurate measurement of residual stresses is crucial for many engineering structures. Fabrication processes such as welding and machining generate residual stresses that are difficult to predict. Residual stresses affect the integrity of structures through promoting failures due to brittle fracture, fatigue, stress corrosion cracking, and wear. In this work, the weight function theory of fracture mechanics is used to measure residual stresses. The weight function theory is an important development in computational fracture mechanics. Stress intensity factors for arbitrary stress distribution on the crack faces can be accurately and efficiently computed for predicting crack growth. This paper demonstrates that the weight functions are equally useful in measuring residual stresses. In this method, an artificial crack is created by a thin cut in a structure containing residual stresses. The cut relieves the residual stresses normal to the crack-face and allows the relieved residual stresses to deform the structure. Strain gages placed adjacent to the cut measure the relieved strains corresponding to incrementally increasing depths of the cut. The weight functions of the cracked body relate the measured strains to the residual stresses normal to the cut within the structure. The procedure details, such as numerical integration of the singular functions in applying the weight function method, will be discussed.

  9. Measurements of residual stress in fracture mechanics coupons

    SciTech Connect

    Prime, Michael B; Hill, Michael R; Nav Dalen, John E

    2010-01-01

    This paper describes measurements of residual stress in coupons used for fracture mechanics testing. The primary objective of the measurements is to quantify the distribution of residual stress acting to open (and/or close) the crack across the crack plane. The slitting method and the contour method are two destructive residual stress measurement methods particularly capable of addressing that objective, and these were applied to measure residual stress in a set of identically prepared compact tension (C(T)) coupons. Comparison of the results of the two measurement methods provides some useful observations. Results from fracture mechanics tests of residual stress bearing coupons and fracture analysis, based on linear superposition of applied and residual stresses, show consistent behavior of coupons having various levels of residual stress.

  10. Measurement of residual stress in bent pipelines

    NASA Astrophysics Data System (ADS)

    Alers, G. A.; McColskey, J. D.

    2002-05-01

    Buried gas and oil pipelines can be subjected to unexpected bending loads caused by such earth movements as earthquakes, wash-outs, road building, or mining subsidence as well as by denting from unintentional digging. In order to make a fitness-for-service assessment, it is necessary to measure any residual stresses that are left in the pipe wall as well as the degree of plastic flow within regions of severe damage. A portable instrument that uses EMATs to rapidly measure ultrasonic shear wave birefringence in the wall of a pipe has been developed and applied to a 5 m (15 ft) long section of 0.56 m (22 in) diameter linepipe loaded in three point bending by a 22 MN (five million pound) load frame. The results showed that: (1) a large correction for shear wave anisotropy caused by texture in the steel had to be introduced and (2) the degree of plastic flow could be deduced from changes in the texture contribution alone. An attempt to separate the stress and texture effects by using SH wave modes in the pipe wall proved unreliable because of magnetostrictive effects in the periodic permanent magnet EMATs used for these experiments.

  11. Residual stress determination from a laser-based curvature measurement

    SciTech Connect

    W. D. Swank; R. A. Gavalya; J. K. Wright; R. N. Wright

    2000-05-08

    Thermally sprayed coating characteristics and mechanical properties are in part a result of the residual stress developed during the fabrication process. The total stress state in a coating/substrate is comprised of the quench stress and the coefficient of thermal expansion (CTE) mismatch stress. The quench stress is developed when molten particles impact the substrate and rapidly cool and solidify. The CTE mismatch stress results from a large difference in the thermal expansion coefficients of the coating and substrate material. It comes into effect when the substrate/coating combination cools from the equilibrated deposit temperature to room temperature. This paper describes a laser-based technique for measuring the curvature of a coated substrate and the analysis required to determine residual stress from curvature measurements. Quench stresses were determined by heating the specimen back to the deposit temperature thus removing the CTE mismatch stress. By subtracting the quench stress from the total residual stress at room temperature, the CTE mismatch stress was estimated. Residual stress measurements for thick (>1mm) spinel coatings with a Ni-Al bond coat on 304 stainless steel substrates were made. It was determined that a significant portion of the residual stress results from the quenching stress of the bond coat and that the spinel coating produces a larger CTE mismatch stress than quench stress.

  12. Residual Stress Determination from a Laser-Based Curvature Measurement

    SciTech Connect

    Swank, William David; Gavalya, Rick Allen; Wright, Julie Knibloe; Wright, Richard Neil

    2000-05-01

    Thermally sprayed coating characteristics and mechanical properties are in part a result of the residual stress developed during the fabrication process. The total stress state in a coating/substrate is comprised of the quench stress and the coefficient of thermal expansion (CTE) mismatch stress. The quench stress is developed when molten particles impact the substrate and rapidly cool and solidify. The CTE mismatch stress results from a large difference in the thermal expansion coefficients of the coating and substrate material. It comes into effect when the substrate/coating combination cools from the equilibrated deposit temperature to room temperature. This paper describes a laser-based technique for measuring the curvature of a coated substrate and the analysis required to determine residual stress from curvature measurements. Quench stresses were determined by heating the specimen back to the deposit temperature thus removing the CTE mismatch stress. By subtracting the quench stress from the total residual stress at room temperature, the CTE mismatch stress was estimated. Residual stress measurements for thick (>1mm) spinel coatings with a Ni-Al bond coat on 304 stainless steel substrates were made. It was determined that a significant portion of the residual stress results from the quenching stress of the bond coat and that the spinel coating produces a larger CTE mismatch stress than quench stress.

  13. Residual stress measurements of tension leg platform tendon welds

    SciTech Connect

    Kim, D.S.; Smith, J.D.

    1994-12-31

    Results of fatigue test of prototype welded tendons showed that fatigue life was greatly reduced for the weld repaired joint. Since tensile residual stresses near the fusion boundary were suspected to cause the fatigue life reduction, these residual stresses were measured. Residual stresses of girth welded tendon pipes for a tension leg platform (TLP) were obtained for various fabrication conditions. The stresses were measured experimentally using the blind hole drilling (BHD) technique, X-ray diffraction (XRD) technique and Barkhausen Noise (BHN) method. The results of these measurements illustrate the reliability of each measurement technique. Effects of joint configuration, weld repair, weld cap grinding, and pre-fatigue test on residual stresses were discussed.

  14. Measured residual stresses in overlay pipe weldments removed from service

    SciTech Connect

    Shack, W.J.

    1985-02-01

    Surface and throughwall residual stresses were measured on an elbow-to-pipe weldment that had been removed from the Hatch-2 reactor about a year after the application of a weld overlay. The results were compared with experimental measurements on three mock-up weldments and with finite-element calculations. The comparison shows that there are significant differences in the form and magnitude of the residual stress distributions. However, even after more than a year of service, the residual stresses over most of the inner surface of the actual plant weldment with an overlay were strongly compressive. 3 refs., 7 figs.

  15. Ultrasonic measurement of residual stress in shot peened aluminum alloy

    NASA Astrophysics Data System (ADS)

    Lavrentyev, Anton I.; Veronesi, William A.

    2001-04-01

    Shot peening is a well-known method for extending the fatigue life of metal components by introducing compressive residual stresses near their surfaces. The capability to non-destructively evaluate the near surface residual stress would greatly aid the assurance of proper fatigue life in shot-peened components. This paper addresses issues encountered in near-surface residual stress measurement by an ultrasonic surface wave method. In this method, a variation of ultrasonic surface wave speed with shot peening intensity is measured. Since the effective wave penetration depth inversely related to the excitation frequency, by making measurements at different frequencies, the method has the potential to provide the stress-depth profile. Experiments were conducted on aluminum specimens (alloy 7075-T7351) peened within the Almen peening intensity from 4A-16A. Several factors were found to contribute to the measured responses: surface roughness, near surface texture change, dislocation density increase and residual stress. In this paper, the contributions of residual stress, dislocation density and surface roughness to the overall effect are separately estimated. It is shown that the experimentally observed velocity change in shot peened samples is dominated by the effect of surface roughness while the role of residual stress is much smaller.

  16. Measuring depth profiles of residual stress with Raman spectroscopy

    SciTech Connect

    Enloe, W.S.; Sparks, R.G.; Paesler, M.A.

    1988-12-01

    Knowledge of the variation of residual stress is a very important factor in understanding the properties of machined surfaces. The nature of the residual stress can determine a part`s susceptibility to wear deformation, and cracking. Raman spectroscopy is known to be a very useful technique for measuring residual stress in many materials. These measurements are routinely made with a lateral resolution of 1{mu}m and an accuracy of 0.1 kbar. The variation of stress with depth; however, has not received much attention in the past. A novel technique has been developed that allows quantitative measurement of the variation of the residual stress with depth with an accuracy of 10nm in the z direction. Qualitative techniques for determining whether the stress is varying with depth are presented. It is also demonstrated that when the stress is changing over the volume sampled, errors can be introduced if the variation of the stress with depth is ignored. Computer aided data analysis is used to determine the depth dependence of the residual stress.

  17. Nondestructive method for measuring residual stresses in metals, a concept

    NASA Technical Reports Server (NTRS)

    Schwebel, C. D.

    1968-01-01

    Nondestructive direct measurement of residual surface stresses in metals can be made because metal under stress has a different electrochemical solution potential than in the unstressed condition. The method uses two matched electrolytic cells to cancel extraneous effects on the actual solution potential of the metal specimen.

  18. Residual Stresses Measured In Quenched HSLA-100 Steel Plate.

    SciTech Connect

    Prime, M. B.

    2005-01-01

    Residual stresses over the cross section of a 60.75 mm thick plate of HSLA-100 steel were measured using the contour method. HSLA-100 is a low carbon, copper precipitation hardened, High-Strength Low-Alloy steel used for naval ship hulls, armor, and containment vessels. The material was prepared by hot cross-rolling, Austenitizing at 900 C for 75 minutes and water quenching, and then tempering at 660 C for 200 minutes followed by another water quench. A cross-sectional map of residual stresses was measured using the contour method: (1) the specimen was carefully cut in two using wire electric discharge machining; (2) the contour of the cut surfaces were measured by using a Coordinate Measuring Machine; and (3) the residual stresses were determined from the measured contours using a 3-D elastic finite element (FE) model. The results showed a typical quenching stress distribution with peak compressive stress of about 165 MPa a few mm below the surface and tensile stress of 200 MPa in the center of the plate thickness. The stress magnitudes, at less than 30% of yield, are somewhat low for water-quenched steels, which is discussed. An FE analysis showed that edge effects in the measured stress map were shown to be consistent with relaxation from removing the test specimen from a larger plate.

  19. Measured Biaxial Residual Stress Maps in a Stainless Steel Weld

    SciTech Connect

    Olson, Mitchell D.; Hill, Michael R.; Patel, Vipul I.; Muransky, Ondrej; Sisneros, Thomas A.

    2015-09-16

    Here, this paper describes a sequence of residual stress measurements made to determine a two-dimensional map of biaxial residual stress in a stainless steel weld. A long stainless steel (316L) plate with an eight-pass groove weld (308L filler) was used. The biaxial stress measurements follow a recently developed approach, comprising a combination of contour method and slitting measurements, with a computation to determine the effects of out-of-plane stress on a thin slice. The measured longitudinal stress is highly tensile in the weld- and heat-affected zone, with a maximum around 450 MPa, and compressive stress toward the transverse edges around ₋250 MPa. The total transverse stress has a banded profile in the weld with highly tensile stress at the bottom of the plate (y = 0) of 400 MPa, rapidly changing to compressive stress (at y = 5 mm) of ₋200 MPa, then tensile stress at the weld root (y = 17 mm) and in the weld around 200 MPa, followed by compressive stress at the top of the weld at around ₋150 MPa. Finally, the results of the biaxial map compare well with the results of neutron diffraction measurements and output from a computational weld simulation.

  20. Measured Biaxial Residual Stress Maps in a Stainless Steel Weld

    DOE PAGES

    Olson, Mitchell D.; Hill, Michael R.; Patel, Vipul I.; ...

    2015-09-16

    Here, this paper describes a sequence of residual stress measurements made to determine a two-dimensional map of biaxial residual stress in a stainless steel weld. A long stainless steel (316L) plate with an eight-pass groove weld (308L filler) was used. The biaxial stress measurements follow a recently developed approach, comprising a combination of contour method and slitting measurements, with a computation to determine the effects of out-of-plane stress on a thin slice. The measured longitudinal stress is highly tensile in the weld- and heat-affected zone, with a maximum around 450 MPa, and compressive stress toward the transverse edges around ₋250more » MPa. The total transverse stress has a banded profile in the weld with highly tensile stress at the bottom of the plate (y = 0) of 400 MPa, rapidly changing to compressive stress (at y = 5 mm) of ₋200 MPa, then tensile stress at the weld root (y = 17 mm) and in the weld around 200 MPa, followed by compressive stress at the top of the weld at around ₋150 MPa. Finally, the results of the biaxial map compare well with the results of neutron diffraction measurements and output from a computational weld simulation.« less

  1. Residual stress measurement and microstructural characterization of thick beryllium films

    SciTech Connect

    Detor, A; Wang, M; Hodge, A M; Chason, E; Walton, C; Hamza, A V; Xu, H; Nikroo, A

    2008-02-11

    Beryllium films are synthesized by a magnetron sputtering technique incorporating in-situ residual stress measurement. Monitoring the stress evolution in real time provides quantitative through-thickness information on the effects of various processing parameters, including sputtering gas pressure and substrate biasing. Specimens produced over a wide range of stress states are characterized via transmission and scanning electron microscopy, and atomic force microscopy, in order to correlate the stress data with microstructure. A columnar grain structure is observed for all specimens, and surface morphology is found to be strongly dependent on processing conditions. Analytical models of stress generation are reviewed and discussed in terms of the observed microstructure.

  2. Optical residual stress measurement in TFT-LCD panels

    NASA Astrophysics Data System (ADS)

    Wang, Wei-Chung; Sung, Po-Chi

    2017-06-01

    The residual stress of the glass substrate might be one of causes to produce the non-uniform light distribution defect, i.e. Mura, in thin film transistor-liquid crystal display (TFT-LCD) panels. Glass is a birefringent material with very low birefringence. Furthermore, the thinner and thinner thickness request from the market makes the traditional photoelasticity almost impossible to measure the residual stresses produced in thin glass plates. Recently, a low-level stress measurement method called transmissivity extremities theory of photoelasticity (TEToP) was successfully developed to measure the residual stress in glass plate. Besides, to measure the stress of the glass plate in the TFT-LCD panel whose rear surface may has different kinds of coatings, an advanced reflection photoelasticity was also developed. In this paper, three commercially available glass plates with 0.33mm nominal thickness and three glass circular disks with different coatings were inspected to verify the feasibility of the TEToP and the advanced reflection photoelasticity, respectively.

  3. Effect of Measured Welding Residual Stresses on Crack Growth

    NASA Technical Reports Server (NTRS)

    Hampton, Roy W.; Nelson, Drew; Doty, Laura W. (Technical Monitor)

    1998-01-01

    Welding residual stresses in thin plate A516-70 steel and 2219-T87 aluminum butt weldments were measured by the strain-gage hole drilling and X-ray diffraction methods. The residual stress data were used to construct 3D strain fields which were modeled as thermally induced strains. These 3D strain fields were then analyzed with the WARP31) FEM fracture analysis code in order to predict their effect on fatigue and on fracture. For analyses of fatigue crack advance and subsequent verification testing, fatigue crack growth increments were simulated by successive saw-cuts and incremental loading to generate, as a function of crack length, effects on crack growth of the interaction between residual stresses and load induced stresses. The specimen experimental response was characterized and compared to the WARM linear elastic and elastic-plastic fracture mechanics analysis predictions. To perform the fracture analysis, the plate material's crack tearing resistance was determined by tests of thin plate M(T) specimens. Fracture analyses of these specimen were performed using WARP31D to determine the critical Crack Tip Opening Angle [CTOA] of each material. These critical CTOA values were used to predict crack tearing and fracture in the weldments. To verify the fracture predictions, weldment M(T) specimen were tested in monotonic loading to fracture while characterizing the fracture process.

  4. Effect of Measured Welding Residual Stresses on Crack Growth

    NASA Technical Reports Server (NTRS)

    Hampton, Roy W.; Nelson, Drew; Doty, Laura W. (Technical Monitor)

    1998-01-01

    Welding residual stresses in thin plate A516-70 steel and 2219-T87 aluminum butt weldments were measured by the strain-gage hole drilling and X-ray diffraction methods. The residual stress data were used to construct 3D strain fields which were modeled as thermally induced strains. These 3D strain fields were then analyzed with the WARP31) FEM fracture analysis code in order to predict their effect on fatigue and on fracture. For analyses of fatigue crack advance and subsequent verification testing, fatigue crack growth increments were simulated by successive saw-cuts and incremental loading to generate, as a function of crack length, effects on crack growth of the interaction between residual stresses and load induced stresses. The specimen experimental response was characterized and compared to the WARM linear elastic and elastic-plastic fracture mechanics analysis predictions. To perform the fracture analysis, the plate material's crack tearing resistance was determined by tests of thin plate M(T) specimens. Fracture analyses of these specimen were performed using WARP31D to determine the critical Crack Tip Opening Angle [CTOA] of each material. These critical CTOA values were used to predict crack tearing and fracture in the weldments. To verify the fracture predictions, weldment M(T) specimen were tested in monotonic loading to fracture while characterizing the fracture process.

  5. Measurement of residual stresses in polymer composites using moire interferometry

    NASA Astrophysics Data System (ADS)

    Shankar, Krishnakumar; Xie, Huimin; Asundi, Anand K.; Oh, Kim E.; Chai, Gin B.

    2001-06-01

    Moire interferometry is employed along with the hole drilling technique to determine residual cure stresses in symmetric cross poly graphite epoxy laminates. Traditional moire interferometry set-up using two collimated angle beams was employed to provide the virtual reference grating while a cross grating with a frequency of 1200 lines per mm was replicated on the specimen surface. Holes of different depths, each one penetrating one additional layer of the laminate, were drilled using a high speed air turbine drill to relieve the stresses in each layer sequentially. The strain distribution around each hole was computed from correlation of the undistorted carrier fringe pattern with the distorted fringe patterns around the holes. The measured strain distributions are compared to residual strain distributions predicted by classical laminate theory.

  6. Residual Stress Measurements After Proof and Flight: ETP-0403

    NASA Technical Reports Server (NTRS)

    Webster, Ronald L..

    1997-01-01

    The intent of this testing was to evaluate the residual stresses that occur in and around the attachment details of a case stiffener segment that has been subjected to flight/recovery followed by proof loading. Not measured in this test were stresses relieved at joint disassembly due to out-of-round and interference effects, and those released by cutting the specimens out of the case segment. The test article was lightweight case stiffener segment 1U50715, S/N L023 which was flown in the forward stiffener position on flight SRM 14A and in the aft position on flight SRM24A. Both of these flights were flown with the 3 stiffener ring configuration. Stiffener L023 had a stiffener ring installed only on the aft stub in its first flight, and it had both rings installed on its second flight. No significant post flight damage was found on either flight. Finally, the segment was used on the DM-8 static test motor in the forward position. No stiffener rings were installed. It had only one proof pressurization prior to assignment to its first use, and it was cleaned and proof tested after each flight. Thus, the segment had seen 3 proof tests, two flight pressurizations, and two low intensity water impacts prior to manufacturing for use on DM-8. On DM-8 it received one static firing pressurization in the horizontal configuration. Residual stresses at the surface and in depth were evaluated by both the x-ray diffraction and neutron beam diffraction methods. The x-ray diffraction evaluations were conducted by Technology for Energy Corporation (TEC) at their facilities in Knoxville, TN. The neutron beam evaluations were done by Atomic Energy of Canada Limited (AECL) at the Chalk River Nuclear Laboratories in Ontario. The results showed general agreement with relatively high compressive residual stresses on the surface and moderate to low subsurface tensile residual stresses.

  7. Estimation of uncertainty for contour method residual stress measurements

    SciTech Connect

    Olson, Mitchell D.; DeWald, Adrian T.; Prime, Michael B.; Hill, Michael R.

    2014-12-03

    This paper describes a methodology for the estimation of measurement uncertainty for the contour method, where the contour method is an experimental technique for measuring a two-dimensional map of residual stress over a plane. Random error sources including the error arising from noise in displacement measurements and the smoothing of the displacement surfaces are accounted for in the uncertainty analysis. The output is a two-dimensional, spatially varying uncertainty estimate such that every point on the cross-section where residual stress is determined has a corresponding uncertainty value. Both numerical and physical experiments are reported, which are used to support the usefulness of the proposed uncertainty estimator. The uncertainty estimator shows the contour method to have larger uncertainty near the perimeter of the measurement plane. For the experiments, which were performed on a quenched aluminum bar with a cross section of 51 × 76 mm, the estimated uncertainty was approximately 5 MPa (σ/E = 7 · 10⁻⁵) over the majority of the cross-section, with localized areas of higher uncertainty, up to 10 MPa (σ/E = 14 · 10⁻⁵).

  8. Estimation of uncertainty for contour method residual stress measurements

    DOE PAGES

    Olson, Mitchell D.; DeWald, Adrian T.; Prime, Michael B.; ...

    2014-12-03

    This paper describes a methodology for the estimation of measurement uncertainty for the contour method, where the contour method is an experimental technique for measuring a two-dimensional map of residual stress over a plane. Random error sources including the error arising from noise in displacement measurements and the smoothing of the displacement surfaces are accounted for in the uncertainty analysis. The output is a two-dimensional, spatially varying uncertainty estimate such that every point on the cross-section where residual stress is determined has a corresponding uncertainty value. Both numerical and physical experiments are reported, which are used to support the usefulnessmore » of the proposed uncertainty estimator. The uncertainty estimator shows the contour method to have larger uncertainty near the perimeter of the measurement plane. For the experiments, which were performed on a quenched aluminum bar with a cross section of 51 × 76 mm, the estimated uncertainty was approximately 5 MPa (σ/E = 7 · 10⁻⁵) over the majority of the cross-section, with localized areas of higher uncertainty, up to 10 MPa (σ/E = 14 · 10⁻⁵).« less

  9. Effects of cutting and specimen size on neutron measurement of residual stresses

    NASA Astrophysics Data System (ADS)

    Law, M.; Luzin, V.; Kirstein, O.

    2010-11-01

    To perform neutron residual stress measurements it is often necessary to cut samples to a manageable size. The effects of cutting a girth welded pipe were investigated with analytical methods and finite element analysis. The effect of cutting on measured stresses was calculated. A simplified method of modelling residual stresses in welds, "chill modelling", is introduced. In ring slitting a cut is made in the axial direction and the deformation is maeesured. The change in elastic stress can be calculated and added to neutron diffraction measurements made on a cut ring to calculate the original stresses. Residual stress measurements were performed to validate the ring slitting correction using ANSTO's residual stress diffractometer Kowari.

  10. Measurement of Residual Stress in a Welded Branch Connection and Effects on Fracture Behaviour

    NASA Astrophysics Data System (ADS)

    Law, M.; Luzin, V.; Kirstein, O.

    2010-11-01

    The branch analysed in this paper was not post weld heat treated, resulting in significant residual stresses. Assessment codes assume these to be at, or close to, yield. An integrity assessment of a welded branch connection was carried out using these high assumed residual stresses. The weld then had residual stresses determined by neutron diffraction, performed using ANSTO's residual stress diffractometer, Kowari. The maximum measured residual stress (290 MPa or 60% of yield) was much lower than the yield value assumed by assessment codes. Reanalysing with the actual residual stresses almost doubled the critical crack size, increasing the safety of the connection.

  11. Residual Stress Measurements of Explosively Clad Cylindrical Pressure Vessels

    SciTech Connect

    Taylor, Douglas J; Watkins, Thomas R; Hubbard, Camden R; Hill, M. R.; Meith, W. A.

    2012-01-01

    Tantalum refractory liners were explosively clad into cylindrical pressure vessels, some of which had been previously autofrettaged. Using explosive cladding, the refractory liner formed a metallurgical bond with the steel of the pressure vessel at a cost of induced strain. Two techniques were employed to determine the residual stress state of the clad steel cylinders: neutron diffraction and mechanical slitting. Neutron diffraction is typically nondestructive; however, due to attenuation along the beam path, the cylinders had to be sectioned into rings that were nominally 25 mm thick. Slitting is a destructive method, requiring the sectioning of the cylindrical samples. Both techniques provided triaxial stress data and useful information on the effects of explosive cladding. The stress profiles in the hoop and radial directions were similar for an autofrettaged, nonclad vessel and a clad, nonautofrettaged vessel. The stress profiles in the axial direction appeared to be different. Further, the data suggested that residual stresses from the autofrettage and explosive cladding processes were not additive, in part due to evidence of reverse yielding. The residual stress data are presented, compared and discussed.

  12. Numerical and neutron diffraction measurement of residual stress distribution in dissimilar weld

    DOE PAGES

    Eisazadeh, Hamid; Bunn, Jeffrey R.; Aidun, Daryush K.

    2017-01-01

    In this study, a model considering an asymmetric power heat distribution, temperature-dependent material properties, strain hardening and phase transformation was developed to predict temperature field and residual stress distribution in GTA dissimilar weld between austenitic stainless steel (304) and low carbon steel (1018). The effect of martensite formation on longitudinal and transverse residual stress distributions were investigated using both FE model and neutron diffraction measurement. The results indicate that martensitic phase has a significant influence on both residual stress components, i.e., transverse and longitudinal, and it not only can change the distribution shape of residual stress near the weld centermore » line but, also, can alter the peak value of the residual stresses. The calculated temperature and weld zone profile were in agreement with the experimental results. Favorable general agreement was also found between the calculated residual stress distribution and residual stress measurements by the neutron diffraction method.« less

  13. Numerical and neutron diffraction measurement of residual stress distribution in dissimilar weld

    SciTech Connect

    Eisazadeh, Hamid; Bunn, Jeffrey R.; Aidun, Daryush K.

    2017-01-01

    In this study, a model considering an asymmetric power heat distribution, temperature-dependent material properties, strain hardening and phase transformation was developed to predict temperature field and residual stress distribution in GTA dissimilar weld between austenitic stainless steel (304) and low carbon steel (1018). The effect of martensite formation on longitudinal and transverse residual stress distributions were investigated using both FE model and neutron diffraction measurement. The results indicate that martensitic phase has a significant influence on both residual stress components, i.e., transverse and longitudinal, and it not only can change the distribution shape of residual stress near the weld center line but, also, can alter the peak value of the residual stresses. The calculated temperature and weld zone profile were in agreement with the experimental results. Favorable general agreement was also found between the calculated residual stress distribution and residual stress measurements by the neutron diffraction method.

  14. Residual stress measurement in a metal microdevice by micro Raman spectroscopy

    NASA Astrophysics Data System (ADS)

    Song, Chang; Du, Liqun; Qi, Leijie; Li, Yu; Li, Xiaojun; Li, Yuanqi

    2017-10-01

    Large residual stress induced during the electroforming process cannot be ignored to fabricate reliable metal microdevices. Accurate measurement is the basis for studying the residual stress. Influenced by the topological feature size of micron scale in the metal microdevice, residual stress in it can hardly be measured by common methods. In this manuscript, a methodology is proposed to measure the residual stress in the metal microdevice using micro Raman spectroscopy (MRS). To estimate the residual stress in metal materials, micron sized β-SiC particles were mixed in the electroforming solution for codeposition. First, the calculated expression relating the Raman shifts to the induced biaxial stress for β-SiC was derived based on the theory of phonon deformation potentials and Hooke’s law. Corresponding micro electroforming experiments were performed and the residual stress in Ni–SiC composite layer was both measured by x-ray diffraction (XRD) and MRS methods. Then, the validity of the MRS measurements was verified by comparing with the residual stress measured by XRD method. The reliability of the MRS method was further validated by the statistical student’s t-test. The MRS measurements were found to have no systematic error in comparison with the XRD measurements, which confirm that the residual stresses measured by the MRS method are reliable. Besides that, the MRS method, by which the residual stress in a micro inertial switch was measured, has been confirmed to be a convincing experiment tool for estimating the residual stress in metal microdevice with micron order topological feature size.

  15. Measuring residual stress in ceramic zirconia-porcelain dental crowns by nanoindentation.

    PubMed

    Zhang, Y; Allahkarami, M; Hanan, J C

    2012-02-01

    Residual stress plays a critical role in failure of ceramic dental crowns. The magnitude and distribution of residual stress in the crown system are largely unknown. Determining the residual stress quantitatively is challenging since the crown has such complex contours and shapes. This work explored the feasibility and validity of measuring residual stress of zirconia and porcelain in ceramic crowns by nanoindentation. Nanoindentation tests were performed on the cross-section of a crown for both porcelain and zirconia along four critical locations: the thickest, thinnest and medium porcelain thicknesses. Zirconia and porcelain pieces, chipped off from the crown and annealed at 400 °C, were used as reference samples. The residual stress was determined by comparing the measured hardness of the stressed sample with that of the reference sample. Nanoindentation impression images were acquired through a scanning probe microscope (SPM) equipped with a Hysitron Triboindenter. Zirconia showed large pile-up. Residual stress is determined along the thickness of crowns at the chosen locations for both porcelain and zirconia. The measured results were compared with the results from X-ray diffraction (XRD) and finite element modeling (FEM). Results show there are large amounts of residual stresses in the dental crown and their magnitude differs between locations due to the complex shape of the crown. The average residual stress readings were as high as -637 MPa and 323 MPa for zirconia and porcelain respectively.

  16. Measurement of the residual stress in hot rolled strip using strain gauge method

    NASA Astrophysics Data System (ADS)

    Kumar, Lokendra; Majumdar, Shrabani; Sahu, Raj Kumar

    2017-07-01

    Measurement of the surface residual stress in a flat hot rolled steel strip using strain gauge method is considered in this paper. Residual stresses arise in the flat strips when the shear cut and laser cut is applied. Bending, twisting, central buckled and edge waviness is the common defects occur during the cutting and uncoiling process. These defects arise due to the non-uniform elastic-plastic deformation, phase transformation occurring during cooling and coiling-uncoiling process. The residual stress analysis is very important because with early detection it is possible to prevent an object from failure. The goal of this paper is to measure the surface residual stress in flat hot rolled strip using strain gauge method. The residual stress was measured in the head and tail end of hot rolled strip considering as a critical part of the strip.

  17. Experiment and numerical simulation for laser ultrasonic measurement of residual stress.

    PubMed

    Zhan, Yu; Liu, Changsheng; Kong, Xiangwei; Lin, Zhongya

    2017-01-01

    Laser ultrasonic is a most promising method for non-destructive evaluation of residual stress. The residual stress of thin steel plate is measured by laser ultrasonic technique. The pre-stress loading device is designed which can easily realize the condition of the specimen being laser ultrasonic tested at the same time in the known stress state. By the method of pre-stress loading, the acoustoelastic constants are obtained and the effect of different test directions on the results of surface wave velocity measurement is discussed. On the basis of known acoustoelastic constants, the longitudinal and transverse welding residual stresses are measured by the laser ultrasonic technique. The finite element method is used to simulate the process of surface wave detection of welding residual stress. The pulsed laser is equivalent to the surface load and the relationship between the physical parameters of the laser and the load is established by the correction coefficient. The welding residual stress of the specimen is realized by the ABAQUS function module of predefined field. The results of finite element analysis are in good agreement with the experimental method. The simple and effective numerical and experimental methods for laser ultrasonic measurement of residual stress are demonstrated.

  18. Residual stresses in material processing

    SciTech Connect

    Kozaczek, K.J.; Watkins, T.R.; Hubbard, C.R.; Wang, Xun-Li; Spooner, S.

    1994-09-01

    Material manufacturing processes often introduce residual stresses into the product. The residual stresses affect the properties of the material and often are detrimental. Therefore, the distribution and magnitude of residual stresses in the final product are usually an important factor in manufacturing process optimization or component life prediction. The present paper briefly discusses the causes of residual stresses. It then adresses the direct, nondestructive methods of residual stress measurement by X-ray and neutron diffraction. Examples are presented to demonstrate the importance of residual stress measurement in machining and joining operations.

  19. A New Methodology For In-Situ Residual Stress Measurement In MEMS Structures

    SciTech Connect

    Sebastiani, M.; Bemporad, E.; Melone, G.; Rizzi, L.; Korsunsky, A. M.

    2010-11-24

    In this paper, a new approach is presented for local residual stress measurement in MEMS structures. The newly proposed approach involves incremental focused ion beam (FIB) milling of annular trenches at material surface, combined with high resolution SEM imaging and Digital Image Correlation (DIC) analysis for the measurement of the strain relief over the surface of the remaining central pillar. The proposed technique allows investigating the average residual stress on suspended micro-structures, with a spatial resolution lower than 1 {mu}m. Results are presented for residual stress measurement on double clamped micro-beams, whose layers are obtained by DC-sputtering (PVD) deposition. Residual stresses were also independently measured by the conventional curvature method (Stoney's equation) on a similar homogeneous coating obtained by the same deposition parameters and a comparison and discussion of obtained results is performed.

  20. A New Methodology For In-Situ Residual Stress Measurement In MEMS Structures

    NASA Astrophysics Data System (ADS)

    Sebastiani, M.; Bemporad, E.; Melone, G.; Rizzi, L.; Korsunsky, A. M.

    2010-11-01

    In this paper, a new approach is presented for local residual stress measurement in MEMS structures. The newly proposed approach involves incremental focused ion beam (FIB) milling of annular trenches at material surface, combined with high resolution SEM imaging and Digital Image Correlation (DIC) analysis for the measurement of the strain relief over the surface of the remaining central pillar. The proposed technique allows investigating the average residual stress on suspended micro-structures, with a spatial resolution lower than 1 μm. Results are presented for residual stress measurement on double clamped micro-beams, whose layers are obtained by DC-sputtering (PVD) deposition. Residual stresses were also independently measured by the conventional curvature method (Stoney's equation) on a similar homogeneous coating obtained by the same deposition parameters and a comparison and discussion of obtained results is performed.

  1. Measuring the residual stress in dental composites using a ring slitting method.

    PubMed

    Park, Jeong Won; Ferracane, Jack L

    2005-09-01

    The objective of this experiment was to employ the ring slitting method for the measurement of the residual stress (RS) produced in dental composite materials after polymerization. This study was designed to determine the effect of slitting and measuring time on the residual stress. Rings were made in a split brass mold from three composites (Z100/3MESPE; Herculite/Kerr; Heliomolar/Ivoclar) and cured in a Triad II (Dentsply). Two points were scribed, and the rings were slit at either 1 h (Early-group) or 24 h (Delayed-group) after curing the composite. The change in the distance between the scribed points was measured using an image analyzer system at both 1 and 24 h after slitting. From the measured change, circumferential RS was calculated and statistically analyzed with ANOVA/Tukey's (P<0.05). The degree of conversion of each composite at 1 and 24 h was measured with FTIR and analyzed using Student's t-test (P<0.05). In general, the residual stress (range=0.42-2.84 MPa) was highest for Z100 and lowest for Heliomolar, but this depended upon the test conditions. The early cut (1 h slitting), 24 h measurement groups showed the highest residual stress values. This study, describes a ring slitting method to measure residual stress generated in dental composites during and after curing. The stress of composite can be affected by the cutting and measurement time.

  2. Barkhausen noise-magnetizing voltage sweep measurement in evaluation of residual stress in hardened components

    NASA Astrophysics Data System (ADS)

    Santa-aho, Suvi; Sorsa, Aki; Hakanen, Merja; Leiviskä, Kauko; Vippola, Minnamari; Lepistö, Toivo

    2014-08-01

    In this study, Barkhausen noise (BN) magnetizing voltage sweep (MVS) measurement is used to evaluate non-destructively the surface residual stress state of hardened components. A new computational feature, where the maximum slope of the sweep is divided by the corresponding magnetizing voltage, is introduced. The results show that this feature has a linear relationship with the residual stress state of the samples. The determination of residual stresses during online production of components is a highly recognized task because tensile stresses may be detrimental to the component. In this study, two sets of hardened samples are used in the analysis. A linear relationship is observed in each sample set indicating that the new feature is applicable in assessment of surface residual stresses of the components.

  3. Remarks on Residual Stress Measurement by Hole-Drilling and Electronic Speckle Pattern Interferometry

    PubMed Central

    2014-01-01

    Hole drilling is the most widespread method for measuring residual stress. It is based on the principle that drilling a hole in the material causes a local stress relaxation; the initial residual stress can be calculated by measuring strain in correspondence with each drill depth. Recently optical techniques were introduced to measure strain; in this case, the accuracy of the final results depends, among other factors, on the proper choice of the area of analysis. Deformations are in fact analyzed within an annulus determined by two parameters: the internal and the external radius. In this paper, the influence of the choice of the area of analysis was analysed. A known stress field was introduced on a Ti grade 5 sample and then the stress was measured in correspondence with different values of the internal and the external radius of analysis; results were finally compared with the expected theoretical value. PMID:25276850

  4. Measurement of residual stress in quenched 1045 steel by the nanoindentation method

    SciTech Connect

    Zhu Lina; Xu Binshi; Wang Haidou; Wang Chengbiao

    2010-12-15

    In this paper, the residual stress in quenched AISI 1045 steel was measured by a recently developed nanoindentation technique. Depth control mode was adopted to measure the residual stress. It was found that residual compressive stress was generated in the quenched steel. The material around nanoindents exhibits significant pile-up deformation. A new method was proposed to determine the real contact area for pile-up material on the basis of invariant pile-up morphology of the loaded or unloaded states. The results obtained by the new method were in good agreement with the residual stresses measured by the classical X-ray diffraction (XRD) method. - Research Highlights: {yields} A new method was proposed to measure the real contact area for pile-up materials. {yields} The real contact depth is defined as the sum of h{sub max} and the pile-up height h{sub p}. {yields} The value of residual stress measured by the nanoindentation method was in good agreement with that by the XRD method.

  5. Effect of Gradients in Multi-Axial Stress States on Residual Stress Measurements with X-Rays.

    DTIC Science & Technology

    1982-03-30

    previous comments on this matter. (5) 2) Analysis of even slightly curved "d" vs sin2* plots assuming a bi-axial surface stress state may cause high...AD-A13 752 NORTHWESTERN UNIV EVANSTON IL DEPT OF MATERIALS SCIENCE F/G 20/3 EFFECT OF GRADIENTS IN MULTI-AXIAL STRESS STATES ON RESIDUAL ST-ETC(U...Research March 30, 1982 Contract N00014-80-C-0116 EFFECT OF GRADIENTS IN MULTI-AXIAL STRESS STATES ON RESIDUAL STRESS MEASUREMENTS WITH X-RAYS by I. C

  6. Practical Application of Residual Stress Measurements on Maritime Vessels

    DTIC Science & Technology

    2012-06-01

    overall weight of the vessel. To get a reduction in weight without reducing functionality , the strategy has been to replace structural components...marine functions . While 5000 series aluminum has the required strength and while it is vulnerable to SCC it retains enough resistance to be useable...aluminum versus steel when aluminum is already has a much smaller resistance to fracture. These stresses can be calculated as a function of the

  7. X-ray diffraction measurement of residual stresses in delta plutonium

    SciTech Connect

    Steinmeyer, P.A.

    1990-09-11

    Residual stresses in delta plutonium can be measured by the x-ray diffractometer method. This was accomplished with the aid of an experimental tantalum x-ray target. Preliminary experiments are encouraging and indicate that stresses may be determined precisely and rapidly. Future work will involve determination of x-ray elastic constants, instrument calibration with stress-free standards, higher x-ray power and more sophisticated monochromatization methods. 4 refs., 4 figs., 1 tab.

  8. Experimental determination of residual stress

    NASA Technical Reports Server (NTRS)

    Ferguson, Milton W.

    1991-01-01

    Residual stresses in finished parts have often been regarded as factors contributing to premature part failure and geometric distortions. Currently, residual stresses in welded structures and railroad components are being investigated. High residual stresses formed in welded structures due primarily to the differential contractions of the weld material as it cools and solidifies can have a profound effect on the surface performance of the structure. In railroad wheels, repeated use of the brakes causes high residual stresses in the rims which may lead to wheel failure and possible derailment. The goals of the study were: (1) to develop strategies for using x-ray diffraction to measure residual stress; (2) to subject samples of Inconel 718 to various mechanical and heat treatments and to measure the resulting stress using x-ray diffraction; and (3) to measure residual stresses in ferromagnetic alloys using magnetoacoustics.

  9. A new nondestructive instrument for bulk residual stress measurement using tungsten kα1 X-ray

    NASA Astrophysics Data System (ADS)

    Ma, Ce; Dou, Zuo-yong; Chen, Li; Li, Yun; Tan, Xiao; Dong, Ping; Zhang, Jin; Zheng, Lin; Zhang, Peng-cheng

    2016-11-01

    We describe an experimental instrument used for measuring nondestructively the residual stress using short wavelength X-ray, tungsten kα1. By introducing a photon energy screening technology, the monochromatic X-ray diffraction of tungsten kα1 was realized using a CdTe detector. A high precision Huber goniometer is utilized in order to reduce the error in residual stress measurement. This paper summarizes the main performance of this instrument, measurement depth, stress error, as opposed to the neutron diffraction measurements of residual stress. Here, we demonstrate an application on the determination of residual stress in an aluminum alloy welded by the friction stir welding.

  10. A new nondestructive instrument for bulk residual stress measurement using tungsten kα1 X-ray.

    PubMed

    Ma, Ce; Dou, Zuo-Yong; Chen, Li; Li, Yun; Tan, Xiao; Dong, Ping; Zhang, Jin; Zheng, Lin; Zhang, Peng-Cheng

    2016-11-01

    We describe an experimental instrument used for measuring nondestructively the residual stress using short wavelength X-ray, tungsten kα1. By introducing a photon energy screening technology, the monochromatic X-ray diffraction of tungsten kα1 was realized using a CdTe detector. A high precision Huber goniometer is utilized in order to reduce the error in residual stress measurement. This paper summarizes the main performance of this instrument, measurement depth, stress error, as opposed to the neutron diffraction measurements of residual stress. Here, we demonstrate an application on the determination of residual stress in an aluminum alloy welded by the friction stir welding.

  11. Evaluation of Procedures in Automated Residual Stress Measurements.

    DTIC Science & Technology

    1977-02-10

    Other , less perfec t systems such as manually repositioning the slit, are likely to cause larger random errors in the measurement. The effect of...justified Eq. 3.12 still depends on the profile being symestric about the peak. Koistinen and arburger ~ 26 ~ sugges t tha t data points for the parabolic

  12. Acoustic Measurements of Residual Stresses and Grain Sizes in Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Fisher, Martin John

    The theory of acoustoelasticity relates the velocity of an acoustic wave in a solid to the elastic stress state in that solid. This thesis presents new theories, measurement techniques, and methodologies related to the use of longitudinal wave acoustoelasticity in aluminum alloys. A one-dimensional model has been developed to provide a simple understanding of the acoustoelastic effect. A new acoustic device for accurately measuring relative thickness variations has been designed and built. This device is used--in conjunction with a pulse-echo phase measurement device and a computer controlled scanning system--to measure acoustic velocity variations in plastically deformed and non-flat-and-parallel samples. Acoustic velocity variations from point to point in an unstressed sample can sometimes be on the same order as velocity changes due to applied or residual stresses, and this can make stress measurements difficult. A statistical theory has been developed to relate these unstressed velocity variations to the average grain size in the sample and to the active area of the acoustic transducer used. Large transducers and small grain sizes will minimize these variations. This relationship has been verified by tests on a number of aluminum alloys and a new method for non-destructive grain size determination has been suggested. A systematic methodology has been developed and tested for studying the influence of uniaxial plastic deformation on the acoustoelastic response. Samples have been plastically deformed in four-point bending to produce elastic-plastic and residual stress states. Acoustic measurements of these stresses have then been compared directly to theoretical predictions based on the materials' stress-strain curves and simple beam theory. In the aluminum alloys tested (2024-T351 and 7075-T651), the acoustoelastic constants are shown to be virtually unchanged by uniaxial plastic strains of less than 2.5%. Thus, the acoustoelastic technique can be reliably

  13. Uncertainty Quantification and Comparison of Weld Residual Stress Measurements and Predictions.

    SciTech Connect

    Lewis, John R.; Brooks, Dusty Marie

    2016-10-01

    In pressurized water reactors, the prevention, detection, and repair of cracks within dissimilar metal welds is essential to ensure proper plant functionality and safety. Weld residual stresses, which are difficult to model and cannot be directly measured, contribute to the formation and growth of cracks due to primary water stress corrosion cracking. Additionally, the uncertainty in weld residual stress measurements and modeling predictions is not well understood, further complicating the prediction of crack evolution. The purpose of this document is to develop methodology to quantify the uncertainty associated with weld residual stress that can be applied to modeling predictions and experimental measurements. Ultimately, the results can be used to assess the current state of uncertainty and to build confidence in both modeling and experimental procedures. The methodology consists of statistically modeling the variation in the weld residual stress profiles using functional data analysis techniques. Uncertainty is quantified using statistical bounds (e.g. confidence and tolerance bounds) constructed with a semi-parametric bootstrap procedure. Such bounds describe the range in which quantities of interest, such as means, are expected to lie as evidenced by the data. The methodology is extended to provide direct comparisons between experimental measurements and modeling predictions by constructing statistical confidence bounds for the average difference between the two quantities. The statistical bounds on the average difference can be used to assess the level of agreement between measurements and predictions. The methodology is applied to experimental measurements of residual stress obtained using two strain relief measurement methods and predictions from seven finite element models developed by different organizations during a round robin study.

  14. Microscopic imaging of residual stress using a scanning phase-measuring acoustic microscope

    NASA Astrophysics Data System (ADS)

    Meeks, Steven W.; Peter, D.; Horne, D.; Young, K.; Novotny, V.

    1989-10-01

    A high-resolution scanning phase-measuring acoustic microscope (SPAM) has been developed and used to image the near-surface residual stress field around features etched in sputtered alumina via the acoustoelastic effect. This microscope operates at 670 MHz and has a resolution of 5-10 microns, depending upon the amount of defocus. Relative velocity changes of sample surface waves as small as 50 ppm are resolved. Images of the stress field at the tip of a 400-micron-wide slot etched in alumina are presented and compared with a finite element simulation. The SPAM uses an unconventional acoustic lens with an anisotropic illumination pattern which can measure anisotropic effects and map residual stress fields with several-micron resolution and a stress sensitivity of 1/3 MPa in an alumina film.

  15. The measurement of X-ray residual stress in textured cubic materials

    NASA Astrophysics Data System (ADS)

    Gazzara, C. P.

    1983-01-01

    An X-ray diffraction procedure for measuring residual stress assumes a linear relationship between the d spacing and sin 2psi in isotropic materials. This study attempts to deal with the use of such a relationship in textured steel and aluminum using parallel beam optics. It was found that a phase difference occurs in the d spacing and the X-ray intensity of the CrK alpha diffraction peak with psi resulting in errors in computing the residual stress. Possible contributing factors are considered, such as systematic errors, specimen preparation, absorption, grain size, and the optical system employed.

  16. Analysis and Measurement of Residual Stress in Bridge Membrane MEMS Relays

    NASA Astrophysics Data System (ADS)

    Ruan, Yong; Wang, Weizhong; Zhu, Yong; You, Zheng

    2017-04-01

    Microelectromechanical system (MEMS) relays are gradually replacing traditional relays because they are smaller and lighter and consume less power. However, performance parameters of MEMS relays, such as the pull-down voltage, response time, and resonant frequency, often deviate from those originally designed, due to residual stress generated during the fabrication process. We present herein a method to measure this residual stress, based on a metal bridge membrane MEMS relay, with the help of a nanoindenter and the finite-element method (FEM). The testing result lies in a reasonable range, indicating that this simple method is reliable and helpful for MEMS relay optimization.

  17. Measuring multiple residual-stress components using the contour method and multiple cuts

    SciTech Connect

    Prime, Michael B; Swenson, Hunter; Pagliaro, Pierluigi; Zuccarello, Bernardo

    2009-01-01

    The conventional contour method determines one component of stress over the cross section of a part. The part is cut into two, the contour of the exposed surface is measured, and Bueckner's superposition principle is analytically applied to calculate stresses. In this paper, the contour method is extended to the measurement of multiple stress components by making multiple cuts with subsequent applications of superposition. The theory and limitations are described. The theory is experimentally tested on a 316L stainless steel disk with residual stresses induced by plastically indenting the central portion of the disk. The stress results are validated against independent measurements using neutron diffraction. The theory has implications beyond just multiple cuts. The contour method measurements and calculations for the first cut reveal how the residual stresses have changed throughout the part. Subsequent measurements of partially relaxed stresses by other techniques, such as laboratory x-rays, hole drilling, or neutron or synchrotron diffraction, can be superimposed back to the original state of the body.

  18. Residual stress measurement by successive extension of a slot: A literature review

    SciTech Connect

    Prime, M.B.

    1997-05-01

    This report reviews the technical literature on techniques that employ successive extension of a slot and the resulting deformations to measure residual stress. Such techniques are known variously in the literature as the compliance or crack compliance method, the successive cracking method, the slotting method, and a fracture mechanics based approach. The report introduces the field and describes the basic aspects of these methods. The report then reviews all literature on the theoretical developments of the method. The theory portion first considers forward method solutions including fracture mechanics, finite element, analytical, and body force methods. Then it examines inverse solutions, including incremental inverses and series expansions. Next, the report reviews all experimental applications of slotting methods. Aspects reviewed include the specimen geometry and material, the details of making the slot, the method used to measure deformation, and the theoretical solutions used to solve for stress. Finally, the report makes a brief qualitative comparison between slotting methods and other residual stress measurement methods.

  19. Residual Stress Measurements with Laser Speckle Correlation Interferometry and Local Heat Treating

    SciTech Connect

    Pechersky, M.J.; Miller, R.F.; Vikram, C.S.

    1994-01-06

    A new experimental technique has been devised to measure residual stresses in ductile materials with a combination of laser speckle pattern interferometry and spot heating. The speckle pattern interferometer measures in-plane deformations while the heating provides for very localized stress relief. The residual stresses are determined by the amount of strain that is measured subsequent to the heating and cool-down of the region being interrogated. A simple lumped parameter model is presented to provide a description of the method. This description is followed by presentations of the results of finite element analyses and experimental results with uniaxial test specimens. Excellent agreement between the experiments and the computer analyses were obtained.

  20. Neutron diffraction measurements of time-dependent residual stresses generated by severe thermomechanical deformation

    SciTech Connect

    Woo, Wan Chuck; Feng, Zhili; Wang, Xun-Li; Hubbard, Camden R

    2009-01-01

    Residual stresses were generated by severe thermomechanical deformation in an aluminum alloy plate. The evolution of the residual stresses during natural aging was investigated by neutron diffraction up to 10,000h. A data reduction method was developed to eliminate microstructure influences (solute variations) on the lattice spacing changes, thereby allowing the determination of the long-range macroscopic residual stresses. The residual stress decreased ({approx}25MPa) with time due to the microstructural modification within the deformed region during natural aging.

  1. Residual stress measurements on a stress relieved Zircaloy-4 weld by neutron diffraction

    NASA Astrophysics Data System (ADS)

    Carr, D. G.; Ripley, M. I.; Brown, D. W.; Vogel, S. C.; Holden, T. M.

    2006-12-01

    The macroscopic stress distribution across an annealed Zircaloy-4 gas tungsten arc weld was measured by neutron time-of-flight diffraction at the SMARTS diffractometer at Los Alamos National Laboratory. The stresses after annealing are about 40% lower than those in the same weld prior to heat treatment. The intergranular strains in the reference coupons, which give the macroscopic stress free lattice spacings, are consistent with the difference in cooling the strongly textured plate and the weakly textured weld.

  2. Residual Stresses in DC cast Aluminum Billet: Neutron Diffraction Measurements and Thermomechanical Modeling

    SciTech Connect

    Drezet, J.-M.; Evans, A.; Pirling, T.

    2011-05-04

    Thermally-induced residual stresses, generated during the industrial Direct Chill casting process of aluminum alloys, can cause both significant safety concerns as well as the formation of defects during down-stream processing. Although these thermally induced strains can be partially relieved by permanent deformation, cracks will be generated either during solidification (hot tears) or post-solidification cooling (cold cracks) when stresses exceed the deformation limit of the alloy. Furthermore, the thermally induced strains result in the presence of large internal stresses within the billet before further processing steps. Although numerical models have been previously developed to compute these residual stresses, most of the computations have been validated only against measured surface distortions. In the present work, the variation in residual elastic strains and stresses in the steady state regime of casting has been measured as a function of radial position using neutron diffraction in an AA6063 grain-refined cylindrical billet. These measurements have been carried out on the same billet section at Poldi at PSI-Villigen and at Salsa at ILL-Grenoble and compare favorably. The results are used to validate a thermo-mechanical finite element casting model and to assess the level of stored elastic energy within the billet.

  3. Residual Stresses in DC cast Aluminum Billet: Neutron Diffraction Measurements and Thermomechanical Modeling

    NASA Astrophysics Data System (ADS)

    Drezet, J.-M.; Evans, A.; Pirling, T.

    2011-05-01

    Thermally-induced residual stresses, generated during the industrial Direct Chill casting process of aluminum alloys, can cause both significant safety concerns as well as the formation of defects during down-stream processing. Although these thermally induced strains can be partially relieved by permanent deformation, cracks will be generated either during solidification (hot tears) or post-solidification cooling (cold cracks) when stresses exceed the deformation limit of the alloy. Furthermore, the thermally induced strains result in the presence of large internal stresses within the billet before further processing steps. Although numerical models have been previously developed to compute these residual stresses, most of the computations have been validated only against measured surface distortions. In the present work, the variation in residual elastic strains and stresses in the steady state regime of casting has been measured as a function of radial position using neutron diffraction in an AA6063 grain-refined cylindrical billet. These measurements have been carried out on the same billet section at Poldi at PSI-Villigen and at Salsa at ILL-Grenoble and compare favorably. The results are used to validate a thermo-mechanical finite element casting model and to assess the level of stored elastic energy within the billet.

  4. Numerical analysis of drilling hole work-hardening effects in hole-drilling residual stress measurement

    NASA Astrophysics Data System (ADS)

    Li, H.; Liu, Y. H.

    2008-11-01

    The hole-drilling strain gage method is an effective semi-destructive technique for determining residual stresses in the component. As a mechanical technique, a work-hardening layer will be formed on the surface of the hole after drilling, and affect the strain relaxation. By increasing Young's modulus of the material near the hole, the work-hardening layer is simplified as a heterogeneous annulus. As an example, two finite rectangular plates submitted to different initial stresses are treated, and the relieved strains are measured by finite element simulation. The accuracy of the measurement is estimated by comparing the simulated residual stresses with the given initial ones. The results are shown for various hardness of work-hardening layer. The influence of the relative position of the gages compared with the thickness of the work-hardening layer, and the effect of the ratio of hole diameter to work-hardening layer thickness are analyzed as well.

  5. Auto-calibration principles for two-dimensional residual stress measurements by Barkhausen noise technique

    NASA Astrophysics Data System (ADS)

    Cikalova, Ulana; Schreiber, Jürgen; Hillmann, Susanne; Meyendorf, Norbert

    2014-02-01

    The magnetic Barkhausen Noise (BN) is well suited to evaluate the effects of mechanical stresses of ferromagnetic materials, e.g. the indirect detection of residual stress states. The most common causes for the occurrence of residual stresses are manufacturing processes, such as casting, welding, machining, forming, heat treatment, etc., consecutive repairs and design changes, and installation or assembly and overloads during the operating life of a construction. A significant calibration effort based on a set of reference values and/or test samples is needed for these measurements, which require a great deal of time and material resources. Additionally, it is impossible to determine the stress states of different components (σxx and σyy) at the surface. Therefore, a new auto-calibration method was developed to analyze two-dimensional stresses. A fixed calibration function based on defined parameters (determined experimentally) was applied. To adjust the auto-calibration function to the experimental reference values by varying functional parameters, a large number of measurement points were used. We present a method that can calculate, based on the multi-dimensional stress state at the measuring point, the stress components σxx and σyy for two perpendicular magnetization directions using the Barkhausen Noise effect.

  6. Thermal input control and enhancement for laser based residual stress measurements using liquid temperature indicating coatings

    DOEpatents

    Pechersky, M.J.

    1999-07-06

    An improved method for measuring residual stress in a material is disclosed comprising the steps of applying a spot of temperature indicating coating to the surface to be studied, establishing a speckle pattern surrounds the spot of coating with a first laser then heating the spot of coating with a far infrared laser until the surface plastically deforms. Comparing the speckle patterns before and after deformation by subtracting one pattern from the other will produce a fringe pattern that serves as a visual and quantitative indication of the degree to which the plasticized surface responded to the stress during heating and enables calculation of the stress. 3 figs.

  7. Method for measuring residual stresses in materials by plastically deforming the material and interference pattern comparison

    DOEpatents

    Pechersky, Martin J.

    1995-01-01

    A method for measuring residual stress in a material comprising the steps of establishing a speckle pattern on the surface with a first laser then heating a portion of that pattern with an infrared laser until the surface plastically deforms. Comparing the speckle patterns before and after deformation by subtracting one pattern from the other will produce a fringe pattern that serves as a visual and quantitative indication of the degree to which the plasticized surface responded to the stress dung heating and enables calculation of the stress.

  8. Thermal input control and enhancement for laser based residual stress measurements using liquid temperature indicating coatings

    DOEpatents

    Pechersky, Martin J.

    1999-01-01

    An improved method for measuring residual stress in a material comprising the steps of applying a spot of temperature indicating coating to the surface to be studied, establishing a speckle pattern surrounds the spot of coating with a first laser then heating the spot of coating with a far infrared laser until the surface plastically deforms. Comparing the speckle patterns before and after deformation by subtracting one pattern from the other will produce a fringe pattern that serves as a visual and quantitative indication of the degree to which the plasticized surface responded to the stress during heating and enables calculation of the stress.

  9. NEUTRON DIFFRACTION MEASUREMENT OF RESIDUAL STRESSES IN FRICTION STIR PROCESSED NANOCOMPOSITE SURFACE LAYER

    SciTech Connect

    Xu, Hanbing; Hubbard, Camden R; An, Ke; Wang, Xun-Li; Feng, Zhili; Qu, Jun

    2009-01-01

    Friction stir processing (FSP) was successfully used to stir and mix nano-sized Al2O3 particles into a Al6061-T6 aluminum plate to form a nanocomposite layer up to 3 mm thick. This nanocomposite surface has demonstrated significantly improved surface hardness, yield strength, and wear-resistance without sacrificing the substrate ductility and conductivity. Neutron diffraction analysis was conducted to determine the residual stress distribution in the nanocomposite surface layer. For comparison, the residual stress of the aluminum surface that was processed similarly but had no particle involved was also measured. Results showed that the macro-level residual stresses in the FSP zone without particles are low due to the annealing effect induced by the long heating time and large heat input. The macro-level residual stresses in the FSP-processed Al-Al2O3 nanocomposite zone are tensile up to 100 MPa in all three directions. The details of the results will be further discussed in the paper.

  10. Residual stresses in a quenched superalloy turbine disc: Measurements and modeling

    NASA Astrophysics Data System (ADS)

    Rist, M. A.; James, J. A.; Tin, S.; Roder, B. A.; Daymond, M. R.

    2006-02-01

    A series of neutron diffraction measurements have been carried out to determine the elastic residual strains deep within a large, 40-cm-diameter, forged and water-quenched IN718 aeroengine compressor disc. Neutron path lengths of up to 6 cm were necessary to probe the thickest parts of the forging, and three-dimensional strain and stress components have been derived for the first time in such a large superalloy specimen. Measurements have been compared with the results from a coupled thermal-mechanical finite-element model of the quenching process, based upon appropriate temperature-dependent material properties, with some success. The general residual stress state in the disc is one of near-surface compression, balanced by tension within the disc interior. The steepest stress and strain gradients occur in the transition region from compression to tension, about 1 cm below the surface all around the disc. The largest stress component is in the disc tangential direction and reaches a magnitude of 400 to 500 MPa near the disc surface and at its core. This exceeds the effective yield stress because of the presence of significant hydrostatic stress.

  11. Triaxial Measurement Method for Analysis of Residual Stress after High Feed Milling by X-Ray Diffraction

    NASA Astrophysics Data System (ADS)

    Čuma, Matúš; Török, Jozef; Telišková, Monika

    2016-12-01

    Surface integrity is a broad term which includes various quality factors affecting the functional properties of parts. Residual stress is one of these factors. Machining generates residual stresses in the surface and subsurface layers of the structural elements. X-ray diffractometry is a non-destructive method applicable for the measurement of residual stresses in surface and subsurface layers of components. The article is focused on the non-destructive progressive method of triaxial measurement of residual stress after machining the surface of sample by high feed milling technology. Significance of triaxial measuring is the capability of measuring in different angles so it is possible to acquire stress tensor containing normal and shear stress components acting in the spot of measuring, using a Cartesian coordinate system.

  12. Tutorial: Understanding residual stress in polycrystalline thin films through real-time measurements and physical models

    NASA Astrophysics Data System (ADS)

    Chason, Eric; Guduru, Pradeep R.

    2016-05-01

    Residual stress is a long-standing issue in thin film growth. Better understanding and control of film stress would lead to enhanced performance and reduced failures. In this work, we review how thin film stress is measured and interpreted. The results are used to describe a comprehensive picture that is emerging of what controls stress evolution. Examples from multiple studies are discussed to illustrate how the stress depends on key parameters (e.g., growth rate, material type, temperature, grain size, morphology, etc.). The corresponding stress-generating mechanisms that have been proposed to explain the data are also described. To develop a fuller understanding, we consider the kinetic factors that determine how much each of these processes contributes to the overall stress under different conditions. This leads to a kinetic model that can predict the dependence of the stress on multiple parameters. The model results are compared with the experiments to show how this approach can explain many features of stress evolution.

  13. Neutron scattering residual stress measurements on gray cast iron brake discs

    SciTech Connect

    Spooner, S.; Payzant, E.A.; Hubbard, C.R.

    1996-11-01

    Neutron diffraction was used to investigate the effects of a heat treatment designed to remove internal residual stresses in brake discs. It is believed that residual stresses may change the rate of deformation of the discs during severe braking conditions when the disc temperature is increased significantly. Neutron diffraction was used to map out residual strain distributions in a production disc before and after a stress-relieving heat treatment. Results from these neutron diffraction experiments show that some residual strains were reduced by as much as 400 microstrain by stress relieving. 5 refs., 5 figs., 1 tab.

  14. Experimental measurement and numerical simulation of residual stresses in a carburized layer of a 5120 steel

    SciTech Connect

    Rangaswamy, P.; Bourke, M.A.M.; Shipley, J.C.; Goldstone, J.A.

    1995-09-01

    A combined experimental and numerical study of residual stress and microstructure has been performed for a carburized steel 5120 specimen. Specimens were cut from 5120 steel bar stock, in the shape of hockey pucks and were subsequently carburized and quenched. X-ray diffraction was used to record stress profiles through the case for the martensite and retained austenite on the two flat surfaces oriented up and down during the quench. Layer removal was performed by electropolishing. Rietveld analysis was used to determine the lattice parameters of the phases at each depth varying with both carbon content and stress. The experimental measurements are compared with a numerical simulation of the phase transformation and the metallurgical changes following the carburization and quench. Results am discussed in the context of the microstructure and the role played by the retained austenite in interpretation. In addition the carbon profile obtained from the lattice parameters is compared with profiles measured using burnout.

  15. Survey of the theory and experimental measurements of residual stress in Pd thin film

    NASA Astrophysics Data System (ADS)

    Afshar, F.; Nazarpour, S.; Cirera, A.

    2010-11-01

    Different thicknesses of Pd thin film were deposited over SrTiO3 by electron beam physical vapor deposition. Residual stress for each thickness of Pd film was computed by applying conventional x-ray diffraction method and taking into account Poisson's ratio and elastic module measured by Nanoindentation. We observed that Pd stress variation at 300 °C substrate temperature obeys the trend of type II metals with high adatom mobility. Several models alluded in the literature were compared to the stress variation of the Pd films. Two models, namely; Freund-Chason and Guisbiers-Van Overschelde-Wautelet were found to be in agreement with the experimental results in that for the thicknesses less than 30 nm, Guisbiers-Van Overschelde-Wautelet is dominant but for higher than 30 nm, variation in stress follows Freund-Chason model. Therefore, the thickness around 30 nm could be considered as coalescence thickness. Surprisingly, this transition thickness is the same thickness that Guisbiers-Van Overschelde-Wautelet and Freund-Chason models intersect. Negligible residual stress and high conductance of 30 nm Pd thin film reveal the importance of this transition thickness in microelectronic technology.

  16. Non-destructive measurement and role of surface residual stress monitoring in residual life assessment of a steam turbine blading material

    NASA Astrophysics Data System (ADS)

    Prabhu-Gaunkar, Gajanana; Rawat, M. S.; Prasad, C. R.

    2014-02-01

    Steam turbine blades in power generation equipment are made from martensitic stainless steels having high strength, good toughness and corrosion resistance. However, these steels are susceptible to pitting which can promote early failures of blades in the turbines, particularly in the low pressure dry/wet areas by stress corrosion and corrosion fatigue. Presence of tensile residual stresses is known to accelerate failures whereas compressive stresses can help in delaying failures. Shot peening has been employed as an effective tool to induce compressive residual stresses which offset a part of local surface tensile stresses in the surface layers of components. Maintaining local stresses at stress raisers, such as pits formed during service, below a threshold level can help in preventing the initiation microcracks and failures. The thickness of the layer in compression will, however, depend of the shot peening parameters and should extend below the bottom of corrosion pits. The magnitude of surface compressive drops progressively during service exposure and over time the effectiveness of shot peening is lost making the material susceptible to micro-crack initiation once again. Measurement and monitoring of surface residual stress therefore becomes important for assessing residual life of components in service. This paper shows the applicability of surface stress monitoring to life assessment of steam turbine blade material based on data generated in laboratory on residual surface stress measurements in relation to fatigue exposure. An empirical model is proposed to calculate the remaining life of shot peened steam turbine blades in service.

  17. Measuring residual stresses in metallic components manufactured with fibre Bragg gratings embedded by selective laser melting

    NASA Astrophysics Data System (ADS)

    Havermann, Dirk; Mathew, Jinesh; MacPherson, William N.; Hand, Duncan P.; Maier, Robert R. J.

    2015-09-01

    Metal clad single mode optical fibres containing Fibre Bragg Gratings are embedded in stainless steel components using bespoke laser based Selective Laser Melting technology (SLM). Significant residual stresses can be created in SLM manufactured components through the strong thermal gradients during the build process. We demonstrate the ability to monitor these internal stresses through embedded optical fibres with FBGs on a layer to layer basis, confirming estimates from models for residual stresses in additive manufactured components.

  18. Residual Stress Changes in Fatigue. Volume 1. Residual Stress Measurements by X-Ray Diffraction in Notched Test Specimens

    DTIC Science & Technology

    1989-03-01

    and the resulting x-ray stresses and error bands leads to several general conclusions: 1) The x-ray stresses (prior to yielding) in virtually all...cN IA __II____ I I I I .9-I LI I elIiAL O O 6p 0 .- .4 r� IS C -Wn FFTF ~F~rF1TFTFFTF~jH ~ U. N IA 35 NADC-88141-60 (Volume 1) 150 - Ti -6A - 4V...porportional counter, mounting brackets, and shaft encoder and motor drive assemblies . Alignment of the sample with respect to the center of rotation

  19. Residual Stress Changes in Fatigue. Volume 2. A Simulation Model for Stress Measurements in Notched Test Specimens by X-Ray Diffraction

    DTIC Science & Technology

    1989-03-01

    Report No. NADC-88141-60 (Volume II) DTIC S F-!. r-CT E MAY 2 6 1~98D RESIDUAL STRESS CHANGES IN FATIGUE VOLUME II - A SIMULATION MODEL FOR STRESS ...Residual Stress Changes in Fatigue: Vol. II. A Simulation Model for Stress Measurements in Notched Test Specimens by X-Ray Diffraction 12 PERSONAL...Simulation; Residual Stress ; X-Ray Difraction ’/ -, . .. 20 11 1 19 ABSTRACT (Continue on reverse if necessary and identif by block number) The state of

  20. Improved measurement of low residual stresses by speckle correlation interferometry and local heat treating

    SciTech Connect

    Pechersky, M.J.

    2000-02-23

    The results presented in this paper clearly demonstrate that the dynamic range of this measurement technique can be improved substantially over the earlier experiments. It is just as clear that a more systematic study must be performed to quantify these improvements and to generate usable calibrations. These results are also encouraging in the sense that this technique may now be appropriate for other materials with high thermal diffusivities. Previous attempts to measure residual stresses by laser annealing and electronic speckle pattern interferometry have been successful for moderate to high stress levels. The method uses an infrared laser for relieving stress in a small spot. A dab on temperature indicating paint is applied to the spot and a specklegram of the spot and the surrounding area is captured. The paint is then heated with a laser until it melts. The heat is transferred from the paint into the metal resulting in a small amount of localized stress relief as the yield stress of the material drops below the stress levels surrounding the spot. Once the spot and area around it have cooled a second speckle-gram is captured and the images are processed to determine the in-plane strain. The amount of stress relief depends on the melting temperature of the paint since yield stress is a function of temperature. The measurement of local stress relief by heating is subject to limitations that result from thermal expansion competing with the reduction in yield stress of the spot at the elevated temperature. That is, as the spot is heated it tends to temporarily reduce the stress in the region surrounding the spot as it expands into this surrounding region. This limits the amount of stress relief that can occur. This can be overcome to some extent by using higher temperature paints, which in turn lowers the yield stress in the heated spot. At some point, however, the thermal expansion overtakes the surrounding stress field and can even drive it into compression

  1. Residual stresses in welded plates

    NASA Technical Reports Server (NTRS)

    Bernstein, Edward L.

    1994-01-01

    The purpose of this project was to develop a simple model which could be used to study residual stress. The mechanism that results in residual stresses in the welding process starts with the deposition of molten weld metal which heats the immediately adjacent material. After solidification of weld material, normal thermal shrinkage is resisted by the adjacent, cooler material. When the thermal strain exceeds the elastic strain corresponding to the yield point stress, the stress level is limited by this value, which decreases with increasing temperature. Cooling then causes elastic unloading which is restrained by the adjoining material. Permanent plastic strain occurs, and tension is caused in the region immediately adjacent to the weld material. Compression arises in the metal farther from the weld in order to maintain overall static equilibrium. Subsequent repair welds may add to the level of residual stresses. The level of residual stress is related to the onset of fracture during welding. Thus, it is of great importance to be able to predict the level of residual stresses remaining after a weld procedure, and to determine the factors, such as weld speed, temperature, direction, and number of passes, which may affect the magnitude of remaining residual stress. It was hoped to use traditional analytical modeling techniques so that it would be easier to comprehend the effect of these variables on the resulting stress. This approach was chosen in place of finite element methods so as to facilitate the understanding of the physical processes. The accuracy of the results was checked with some existing experimental studies giving residual stress levels found from x-ray diffraction measurements.

  2. Experimental measurements of surface damage and residual stresses in micro-engineered plasma facing materials

    NASA Astrophysics Data System (ADS)

    Rivera, David; Wirz, Richard E.; Ghoniem, Nasr M.

    2017-04-01

    The thermomechanical damage and residual stresses in plasma-facing materials operating at high heat flux are experimentally investigated. Materials with micro-surfaces are found to be more resilient, when exposed to cyclic high heat flux generated by an arc-jet plasma. An experimental facility, dedicated to High Energy Flux Testing (HEFTY), is developed for testing cyclic heat flux in excess of 10 MW/m2. We show that plastic deformation and subsequent fracture of the surface can be controlled by sample cooling. We demonstrate that W surfaces with micro-pillar type surface architecture have significantly reduced residual thermal stresses after plasma exposure, as compared to those with flat surfaces. X-ray diffraction (XRD) spectra of the W-(110) peak reveal that broadening of the Full Width at Half Maximum (FWHM) for micro-engineered samples is substantially smaller than corresponding flat surfaces. Spectral shifts of XRD signals indicate that residual stresses due to plasma exposure of micro-engineered surfaces build up in the first few cycles of exposure. Subsequent cyclic plasma heat loading is shown to anneal out most of the built-up residual stresses in micro-engineered surfaces. These findings are consistent with relaxation of residual thermal stresses in surfaces with micro-engineered features. The initial residual stress state of highly polished flat W samples is compressive (≈ -1.3 GPa). After exposure to 50 plasma cycles, the surface stress relaxes to -1.0 GPa. Micro-engineered samples exposed to the same thermal cycling show that the initial residual stress state is compressive at (- 250 MPa), and remains largely unchanged after plasma exposure.

  3. ETP-0492, Measured Residual Stresses in CYL S/N 53 Fretted Area

    NASA Technical Reports Server (NTRS)

    Webster, Ronald L.

    1998-01-01

    This test report presents the results of a residual stress survey of the inner clevis leg of lightweight cylinder SIN 053 as described by ETP-0492. The intent of this testing was to evaluate the residual stresses that occur in and around the inner clevis leg at the capture feature contact zone during a normal flight cycle. Lightweight case cylinder segment IU50717, S/N L053 from Flight STS-27 exhibited fretting around the contact zone of the inner clevis leg and the capture feature of the field joint. Post flight inspection revealed several large fitting pits on the inside of the inner clevis leg. This cylinder was assigned for both residual stress and metallurgical evaluation. This report is concerned only with the residual so= evaluations. The effects of glass bead cleaning and fi=ing were evaluated using the x-ray diffraction method.

  4. Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

    NASA Astrophysics Data System (ADS)

    Ahmad, Bilal; Fitzpatrick, Michael E.

    2016-01-01

    The contour method of residual stress measurement relies on the careful application of wire electro-discharge machining (WEDM) for the cutting stage. Changes in material removal rates during the cut lead to errors in the final calculated values of residual stress. In this study, WEDM cutting parameters have been explored to identify the optimum conditions for contour method residual stress measurements. The influence of machine parameters on the surface roughness and cutting artifacts in the contour cut is discussed. It has been identified that the critical parameter in improving the surface finish is the spark pulse duration. A typical cutting artifact and its impact on measured stress values have been identified and demonstrated for a contour cut in a welded marine steel. A procedure is presented to correct contour displacement data from the influence of WEDM cutting artifacts, and is demonstrated on the correction of a measured weld residual stress. The corrected contour method improved the residual stress magnitude up to 150 MPa. The corrected contour method results were validated by X-ray diffraction, incremental center hole drilling, and neutron diffraction.

  5. Development of Laser Ultrasonic Device for Residual Stress Measurement in Welded Structures

    SciTech Connect

    Subudhi, Manomohan

    2009-03-31

    A CRADA project was performed between BNL and SpectraQuest, Inc. of Richmond, Virginia under the auspices of IPP with the DOE support. The purpose was to jointly support Prokhorov General Physics Institute (GPI), Russian Academy of Sciences of Russia to develop a prototype Laser Ultrasonic Impact Testing (LUIT) device which could be commercialized and marketed. The device is based on laser-generated ultrasonic waves and can be used for measuring residual stresses in welded structures using a nondestructive technique. The work was performed from October 1, 2003 to September 30, 2009. The project resulted in development and validation of a prototype LUIT device. GPI - BNL – SpectraQuest partnership developed the LUIT device to the point where it could be commercialized and marketed for the special applications in the manufacturing field.

  6. Residual stress measurements via neutron diffraction of additive manufactured stainless steel 17-4 PH.

    PubMed

    Masoomi, Mohammad; Shamsaei, Nima; Winholtz, Robert A; Milner, Justin L; Gnäupel-Herold, Thomas; Elwany, Alaa; Mahmoudi, Mohamad; Thompson, Scott M

    2017-08-01

    Neutron diffraction was employed to measure internal residual stresses at various locations along stainless steel (SS) 17-4 PH specimens additively manufactured via laser-powder bed fusion (L-PBF). Of these specimens, two were rods (diameter=8 mm, length=80 mm) built vertically upward and one a parallelepiped (8×80×9 mm(3)) built with its longest edge parallel to ground. One rod and the parallelepiped were left in their as-built condition, while the other rod was heat treated. Data presented provide insight into the microstructural characteristics of typical L-PBF SS 17-4 PH specimens and their dependence on build orientation and post-processing procedures such as heat treatment. Data have been deposited in the Data in Brief Dataverse repository (doi:10.7910/DVN/T41S3V).

  7. RAPID COMMUNICATION: Measurement of residual stresses around Vickers indentations in a ruby crystal using a Raman luminescence microscope

    NASA Astrophysics Data System (ADS)

    Banini, G. K.; Chaudhri, M. M.; Smith, T.; Hayward, I. P.

    2001-11-01

    A Raman luminescence microscope has been used to determine the residual stresses around Vickers diamond indentations in a relatively large, well-polished, R-cut (10 bar 1 2) ruby single crystal. The principle of the method is based on the fact that the frequencies of the luminescence R lines of the ruby shift in a systematic manner with applied stress. It is shown that the hydrostatic component of the residual stress around a 25 N Vickers indentation can be as high as about 2 GPa, and that its magnitude decreases as A/r3, where r is the distance from the centre of indentation and A is a constant. These measurements are shown to be in qualitative agreement with the predictions of the current analytical models, although the magnitudes of the measured residual stresses are an order of magnitude smaller than those predicted by theory. Possible reasons for these differences are discussed.

  8. Comparison of measured temperatures, thermal stresses and creep residues with predictions on a built-up titanium structure

    NASA Technical Reports Server (NTRS)

    Jenkins, Jerald M.

    1987-01-01

    Temperature, thermal stresses, and residual creep stresses were studied by comparing laboratory values measured on a built-up titanium structure with values calculated from finite-element models. Several such models were used to examine the relationship between computational thermal stresses and thermal stresses measured on a built-up structure. Element suitability, element density, and computational temperature discrepancies were studied to determine their impact on measured and calculated thermal stress. The optimum number of elements is established from a balance between element density and suitable safety margins, such that the answer is acceptably safe yet is economical from a computational viewpoint. It is noted that situations exist where relatively small excursions of calculated temperatures from measured values result in far more than proportional increases in thermal stress values. Measured residual stresses due to creep significantly exceeded the values computed by the piecewise linear elastic strain analogy approach. The most important element in the computation is the correct definition of the creep law. Computational methodology advances in predicting residual stresses due to creep require significantly more viscoelastic material characterization.

  9. Validation of a Residual Stress Measurement Method by Swept High-Frequency Eddy Currents

    NASA Astrophysics Data System (ADS)

    Lee, C.; Shen, Y.; Lo, C. C. H.; Nakagawa, N.

    2007-03-01

    This paper reports on a swept high-frequency eddy current (SHFEC) measurement method developed for electromagnetic nondestructive characterization of residual stresses in shot peened aerospace materials. In this approach, we regard shot-peened surfaces as modified surface layers of varying conductivity, and determine the conductivity deviation profile by inversion of the SHFEC data. The SHFEC measurement system consists of a pair of closely matched printed-circuit-board coils driven by laboratory instrument under software control. This provides improved sensitivity and high frequency performance compared to conventional coils, so that swept frequency EC measurements up to 50 MHz can be made to achieve the smallest skin depth of 80 μm for nickel-based superalloys. We devised a conductivity profile inversion procedure based on the laterally uniform multi-layer theory of Cheng, Dodd and Deeds. The main contribution of this paper is the methodology validation. Namely, the forward and inverse models were validated against measurements on artificial layer specimens consisting of metal films with different conductivities placed on a metallic substrate. The inversion determined the film conductivities which were found to agree with those measured using the direct current potential drop (DCPD) method.

  10. Nondestructive measurement and analysis of residual stress in and around welds--A state of the art survey

    SciTech Connect

    Not Available

    1993-07-01

    One objective of mechanical design of welded fabrications is to compensate loads by stresses which the materials used in structural components can accommodate. Beside these load-induced stresses, residual stresses also have to be considered. These residual stresses are built up during weld pool cooling. All welded structures therefore have residual stresses, which can be relieved by heat treatment to below the yield-stress level at the annealing temperature. If not fully relieved, their presence can accelerate corrosion and corrosive cracking of welds. Quality assurance of welded structures needs tools for quantitative nondestructive analysis of stress states. The only nondestructive technique specifically developed for measurement and analysis of stress states is x-ray diffraction. Special devices for application under industrial or on-site environments have been developed and are extensively used. This type of measurement can be time-consuming, depending on the equipment, and has practical limitations. Moreover the penetration of x-rays into metals is small, in the order of 30 microns, and the measurements can be affected by other surface-related disturbance caused by machining and surface finishing. In the last ten years extensive research and development has been done to develop stress-analyzing techniques of a typical ndt-style,'' i.e., the use of a probe manipulated by hand or a manipulator, together with portable equipment. The present state of development of such an approach and the most important results obtained up to now are described in the following article.

  11. Hall coefficient measurement for residual stress assessment in precipitation hardened IN718 nickel-base superalloy

    NASA Astrophysics Data System (ADS)

    Velicheti, Dheeraj; Nagy, Peter B.; Hassan, Waled

    2017-02-01

    We investigated the feasibility of residual stress assessment based on Hall coefficient measurements in precipitation hardened IN718 nickel-base superalloy. As a first step, we studied the influence of microstructural variations on the galvanomagnetic properties of IN718 nickel-base superalloy. We found that the Hall coefficient of IN718 increases from ≈ 8.0×10-11 m3/C in its fully annealed state of 15 HRC Rockwell hardness to ≈ 9.4×10-11 m3/C in its fully hardened state of 45 HRC. We also studied the influence of cold work, i.e., plastic deformation, at room temperature and found that cold work had negligible effect on the Hall coefficient of fully annealed IN718, but significantly reduced it in hardened states of the material. For example, measurements conducted on fully hardened IN718 specimens showed that the Hall coefficient decreased more or less linearly with cold work from its peak value of ≈ 9.4×10-11 m3/C in its intact state to ≈ 9.0×10-11 m3/C in its most deformed state of 22% plastic strain. We also studied the influence of applied stress and found that elastic strain significantly increases the Hall coefficient of IN718 regardless of the state of hardening. The relative sensitivity of the Hall coefficient to elastic strain was measured as a unitless gauge factor K that is defined as the ratio of the relative change of the Hall coefficient ΔRH/RH divided by the axial strain ɛ = σ/E, where σ is the applied uniaxial stress and E is the Young's modulus of the material. We determined that the galvanomagnetic gauge factor of IN718 is κ ≈ 2.6 - 2.9 depending on the hardness level. Besides the fairly high value of the gauge factor, it is important that it is positive, which means that compressive stress in surface-treated components decreases the Hall coefficient in a similar way as plastic deformation does, therefore the unfortunate cancellation that occurs in fully hardened IN718 in the case of electric conductivity measurements will not

  12. On the use of the hole-drilling technique for residual stress measurements in thin plates

    NASA Technical Reports Server (NTRS)

    Hampton, R. W.; Nelson, D. V.

    1992-01-01

    The strain gage blind hole-drilling technique may be used to determine residual stresses at and below the surface of components. In this paper, the hole-drilling analysis methodology for thick plates is reviewed, and experimental data are used to evaluate the methodology and to assess its applicability to thin plates. Data on the effects of gage pattern, surface preparation, hole spacing, hole eccentricity, and stress level are also presented.

  13. Quenching and Cold-Work Residual Stresses in Aluminum Hand Forgings : Contour Method Measurement and FEM Prediction

    SciTech Connect

    Prime, M. B.; Newborn, M. A.; Balog, J. A.

    2003-01-01

    The cold-compression stress relief process used to reduce the quench-induced stresses in high-strength aerospace aluminum alloy forgings does not fully relieve the stresses. This study measured and predicted the residual stress in 7050-T74 (solution heat treated, quenched, and artificially overaged) and 7050-T7452 (cold compressed prior to aging) hand forgings. The manufacturing process was simulated by finite element analysis. First, a thermal analysis simulated the quench using appropriate thermal boundary conditions and temperature dependent material properties. Second, a structural analysis used the thermal history and a temperature and strain-rate dependent constitutive model to predict the stresses after quenching. Third, the structural analysis was continued to simulate the multiple cold compressions of the stress relief process. Experimentally, the residual stresses in the forgings were mapped using the contour method, which involved cutting the forgings using wire EDM and then measuring the contour of the cut surface using a CMM. Multiple cuts were used to map different stress components. The results show a spatially periodic variation of stresses that results from the periodic nature of the cold work stress relief process. The results compare favorably with the finite element prediction of the stresses.

  14. Measurement of residual stresses in deposited films of SOFC component materials

    SciTech Connect

    Kato, T.; Momma, A.; Nagata, S.; Kasuga, Y.

    1996-12-31

    The stress induced in Solid oxide fuel cells (SOFC)s has important influence on the lifetime of SOFC. But the data on stress in SOFC and mechanical properties of SOW component materials have not been accumulated enough to manufacture SOFC. Especially, the data of La{sub 1-x}Sr{sub x}MnO{sub 3} cathode and La{sub 1-x}Sr{sub x}CrO{sub 3} interconnection have been extremely limited. We have estimated numerically the dependences of residual stress in SOFC on the material properties, the cell structure and the fabrication temperatures of the components, but these unknown factors have caused obstruction to simulate the accurate behavior of residual stress. Therefore, the residual stresses in deposited La{sub 1-x}Sr{sub x}MnO{sub 3} and La{sub 1-x}Sr{sub x}CrO{sub 3} films are researched by the observation of the bending behavior of the substrate strips. The films of SOFC component materials were prepared by the RF sputtering method, because: (1) It can fabricate dense films of poor sinterable material such as La{sub 1-x}Sr{sub x}CrO{sub 3} compared with sintering or plasma spray method. (2) For the complicated material such as perovskite materials, the difference between the composition of a film and that of a target material is generally small. (3) It can fabricate a thick ceramics film by improving of the deposition rate. For example, Al{sub 2}O{sub 3} thick films of 50{mu}m can be fabricated with the deposition rate of approximately 5{mu}m/h industrially. In this paper, the dependence of residual stress on the deposition conditions is defined and mechanical properties of these materials are estimated from the results of the experiments.

  15. Measuring residual stress of anisotropic thin film by fast Fourier transform.

    PubMed

    Tien, Chuen-Lin; Zeng, Hung-Da

    2010-08-02

    A new method for the measurement of anisotropic stress in thin films based on 2-D fast Fourier transform (FFT) is presented. A modified Twyman-Green interferometer was used for surface topography measurement. A fringe normalization technique was also used to improve the phase extraction technique efficiently. The measurement of anisotropic stress in obliquely deposited MgF(2) thin film was demonstrated.

  16. In Situ Tensile Deformation and Residual Stress Measurement by Neutron Diffraction in Modified 9Cr-1Mo Steel

    NASA Astrophysics Data System (ADS)

    Shrestha, Triratna; Charit, Indrajit; Potirniche, Gabriel

    2015-12-01

    The deformation behavior of monolithic modified 9Cr-1Mo (Grade 91) steel during uniaxial tensile loading was studied using the in situ neutron diffraction technique. The residual stress distribution across gas tungsten arc welds in the Grade 91 steel was measured by the time-of-flight neutron diffraction method using the SMARTS diffractometer at Lujan Neutron Scattering Center, Los Alamos National Laboratory. Grade 91 plates were welded using the gas tungsten arc welding (GTAW) technique. The load sharing by different grain orientations was observed during the tensile loading. The residual stresses along three orthogonal directions were determined at the mid-thickness, 4.35 and 2.35 mm below the surface of both the as-welded and post-weld heat-treated plates. The residual stresses of the as-welded plates were compared with those of the post-weld heat-treated plates. The post-weld heat treatment significantly reduced the residual stress level in the base metal, the heat-affected zone, and the weld zone. Vickers microhardness across the weld zone of the as-welded and post-weld heat-treated specimens was evaluated and correlated with the observed residual stress profile and microstructure.

  17. Optical loss and residual stress measurement of infrared chalcogenide glasses and analysis on its influencing factors

    NASA Astrophysics Data System (ADS)

    Song, Baoan; Yang, Yan; Jia, Zhitai; Chen, Feifei; Lin, Changgui; Dai, Shixun; Wang, Xunsi; Shen, Xiang; Xu, Tiefeng; Nie, Qiuhua

    2013-06-01

    Chalcogenide glasses (ChGs) have a relatively small temperature coefficient of refractive index, broad transmission range from almost visible to mid-infrared. It is suitable for precision molding. With the help of above mentioned merits, ChGs have a vast reservoir of value in the field of military and civilian infrared imaging. However, the internal defects of ChGs are caused by melting, cool-demoulding and annealing in a high vacuumed ampoule. The defects include the optical inhomogeneity, chemical inhomogeneity and built-in stress which trouble the homogeneity of ChGs and directly affect the imaging quality of infrared imaging devices. The detection and control of internal defects is a key technique. In this paper the platform for testing, characterization and evaluation of the inhomogeneity of ChGs will be designed and built. The appropriate testing and evaluation criteria of inhomogeneity during the preparation procedure of ChGs in the vacuumed ampoule will be studied. The transmittance of ChGs sample is measured repeatedly. The factor of internal multple reflection in ChGs sample is analysed and discussed. Analysis shows that the mean transmissivity of ChGs sample (Ge28Sb12Se60) with thick of 1 cm is approximately 66% in 8 to 11 microns. The loss is less than 2.40%/cm. The optical path difference (OPD) caused by residual stress in ChGs sample is less than 5.2 nm/cm. The results will provide a technical support to optimize the ChGs preparation process and improve the ChGs homogeneity.

  18. Tensile Straightening of Superfine Wire and Residual Stress Measurement Using Focused Ion Beam

    NASA Astrophysics Data System (ADS)

    Yamashita, Tsutomu; Yoshida, Kazunari

    The general method of reducing curving or bending for midsize wires or sheets is straightening using rollers and/or levelers. For superfine wires, similarly, high straightness is needed. However, it is very difficult to deal with superfine wires due to their fineness and low tensile strength. In our study, warm tensile straightening processes for superfine gold wire, which is widely used as bonding material between leads and IC chips in semiconductors, were examined. Furthermore, finite element analyses of drawing and tensile straightening of superfine wires were carried out. The correlation between straightness and axial residual stress, which was calculated using the curve width when half of the wire was removed by sputtering with a focused ion beam (FIB), was studied. As a result of our studies, the improvement of straightness by tensile straightening of superfine gold wire was demonstrated, and the relationship between axial residual stress and straightness of wires was clarified.

  19. Influence of thermal expansion mismatch on residual stress profile in veneering ceramic layered on zirconia: Measurement by hole-drilling.

    PubMed

    Mainjot, Amélie K; Najjar, Achref; Jakubowicz-Kohen, Boris D; Sadoun, Michaël J

    2015-09-01

    Mismatch in thermal expansion coefficient between core and veneering ceramic (Δα=αcore-αveneer, ppm/°C) is reported as a crucial parameter influencing veneer fractures with Yttria-tetragonal-zirconia-polycrystal (Y-TZP) prostheses, which still constitutes a misunderstood problem. However, the common positive Δα concept remains empirical. The objective of this study is to investigate the Δα dependence of residual stress profiles in veneering ceramic layered on Y-TZP frameworks. The stress profile was measured with the hole-drilling method in bilayered disc samples of 20mm diameter with a 0.7mm thick Y-TZP framework and a 1.5mm thick veneer layer. 3 commercial and 4 experimental veneering ceramics (n=3 per group) were used to obtain different Δα varying from -1.3ppm/°C to +3.2ppm/°C, which were determined by dilatometric analyses. Veneer fractures were observed in samples with Δα≥+2.3 or ≤-0.3ppm/°C. Residual stress profiles measured in other groups showed compressive stresses in the surface, these stresses decreasing with depth and then becoming more compressive again near the interface. Small Δα variations were shown to induce significant changes in residual stress profiles. Compressive stress near the framework was found to decrease inversely to Δα. Veneer CTE close to Y-TZP (+0.2ppm/°C Δα) gived the most favorable stress profile. Yet, near the framework, Δα-induced residual stress varied inversely to predictions. This could be explained by the hypothesis of structural changes occurrence within the Y-TZP surface. Consequently, the optimum Δα value cannot be determined before understanding Y-TZP's particular behavior when veneered. Copyright © 2015 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  20. Residual Stress Measurement and Calibration for A7N01 Aluminum Alloy Welded Joints by Using Longitudinal Critically Refracted ( LCR) Wave Transmission Method

    NASA Astrophysics Data System (ADS)

    Zhu, Qimeng; Chen, Jia; Gou, Guoqing; Chen, Hui; Li, Peng; Gao, W.

    2016-10-01

    Residual stress measurement and control are highly important for the safety of structures of high-speed trains, which is critical for the structure design. The longitudinal critically refracted wave technology is the most widely used method in measuring residual stress with ultrasonic method, but its accuracy is strongly related to the test parameters, namely the flight time at the free-stress condition ( t 0), stress coefficient ( K), and initial stress (σ0) of the measured materials. The difference of microstructure in the weld zone, heat affected zone, and base metal (BM) results in the divergence of experimental parameters. However, the majority of researchers use the BM parameters to determine the residual stress in other zones and ignore the initial stress (σ0) in calibration samples. Therefore, the measured residual stress in different zones is often high in errors and may result in the miscalculation of the safe design of important structures. A serious problem in the ultrasonic estimation of residual stresses requires separation between the microstructure and the acoustoelastic effects. In this paper, the effects of initial stress and microstructure on stress coefficient K and flight time t 0 at free-stress conditions have been studied. The residual stress with or without different corrections was investigated. The results indicated that the residual stresses obtained with correction are more accurate for structure design.

  1. Measurement of residual stress fields in FHPP welding: a comparison between DSPI combined with hole-drilling and neutron diffraction

    NASA Astrophysics Data System (ADS)

    Viotti, Matias R.; Albertazzi, Armando; Staron, Peter; Pisa, Marcelo

    2013-04-01

    This paper shows a portable device to measure mainly residual stress fields outside the optical bench. This system combines the traditional hole drilling technique with Digital Speckle Pattern Interferometry. The novel feature of this device is the high degree of compaction since only one base supports simultaneously the measurement module and the hole-drilling device. The portable device allows the measurement of non-uniform residual stresses in accordance with the ASTM standard. In oil and gas offshore industries, alternative welding procedures among them, the friction hydro pillar processing (FHPP) is highlighted and nowadays is an important maintenance tool since it has the capability to produce structure repairs without risk of explosions. In this process a hole is drilled and filled with a consumable rod of the same material. The rod, which could be cylindrical or conical, is rotated and pressed against the hole, leading to frictional heating. In order to assess features about the residual stress distribution generated by the weld into the rod as well as into the base material around the rod, welded samples were evaluated by neutron diffraction and by the hole drilling technique having a comparison between them. For the hole drilling technique some layers were removed by using electrical discharge machining (EDM) after diffraction measurements in order to assess the bulk stress distribution. Results have shown a good agreement between techniques.

  2. Determination of calibration constants for the hole-drilling residual stress measurement technique applied to orthotropic composites. II - Experimental evaluations

    NASA Technical Reports Server (NTRS)

    Prasad, C. B.; Prabhakaran, R.; Tompkins, S.

    1987-01-01

    The first step in the extension of the semidestructive hole-drilling technique for residual stress measurement to orthotropic composite materials is the determination of the three calibration constants. Attention is presently given to an experimental determination of these calibration constants for a highly orthotropic, unidirectionally-reinforced graphite fiber-reinforced polyimide composite. A comparison of the measured values with theoretically obtained ones shows agreement to be good, in view of the many possible sources of experimental variation.

  3. Determination of calibration constants for the hole-drilling residual stress measurement technique applied to orthotropic composites. II - Experimental evaluations

    NASA Technical Reports Server (NTRS)

    Prasad, C. B.; Prabhakaran, R.; Tompkins, S.

    1987-01-01

    The first step in the extension of the semidestructive hole-drilling technique for residual stress measurement to orthotropic composite materials is the determination of the three calibration constants. Attention is presently given to an experimental determination of these calibration constants for a highly orthotropic, unidirectionally-reinforced graphite fiber-reinforced polyimide composite. A comparison of the measured values with theoretically obtained ones shows agreement to be good, in view of the many possible sources of experimental variation.

  4. Residual stress relaxation measurements across interfaces at macro-and micro-scales using slitting and DIC

    NASA Astrophysics Data System (ADS)

    Blair, A.; Daynes, N.; Hamilton, D.; Horne, G.; Heard, P. J.; Hodgson, D. Z. L.; Scott, T. B.; Shterenlikht, A.

    2009-08-01

    In this paper digital image correlation is used to measure relaxation of residual stresses across an interface. On the macro scale the method is applied to a tri-layer bonded aluminium sample, where the middle layer is in tension and the top and the bottom layers are in compression. High contrast speckle pattern was sprayed onto the surface. The relaxation was done with the slitting saw. Three dimensional image correlation was used. On the micro scale the technique was applied to a heat treated large grain brass loaded in tension. Mechanical and electro polishing was used for surface preparation. A focused ion beam was used for slitting across a grain boundary and for imaging. Grain orientation was measured using electron back-scattering diffraction. Two dimensional image correlation was employed. In all macro- and micro-scale experiments the range of measured relaxation was sub-pixel, almost at the limit of the resolution of the image correlation algorithms. In the macro-scale experiments, the limiting factor was low residual stress, due to low shear strength of the Araldite glue used for bonding. Finite element simulation of the relaxation agreed only qualitatively with the experimental results at both size scales. The methodology is intended for use with inverse methods, i.e. the measured relaxation is applied as the boundary conditions to an appropriate FE model which produces stresses equal to the relaxed residual stresses, but with opposite sign. The main conclusion is that the digital image correlation method could be used to measure relaxation caused by slitting in heterogeneous materials and structures at both macro- and micro-scales. However, the repeatability of the techniques needs to be improved before residual stresses can be determined confidently. Acknowledgments The authors gratefully acknowledge Airbus UK for provision of materials. They thank Dr Richard Burguete, Airbus UK, and Prof Peter Flewitt, Department of Physics, University of Bristol, for

  5. RESIDUAL STRESS IN HARDENED STEEL CYLINDERS

    DTIC Science & Technology

    ultimate strength of the steel and in some instances caused cracking, and (4) stress patterns of interrupted quench specimens were not consistent enough to warrant a conclusion. (Author)...A study was conducted to (1) measure residual stress in hardened steel solid cylinders, (2) correlate the stress values with heat treatments, and (3...develop a dissolution technique. Residual stress patterns for 12 solid cylinders of 4160 steel, heat treated by various methods, were determined

  6. A Comparison of Residual Stress Measuring Techniques: Their Strengths and Weaknesses

    DTIC Science & Technology

    1980-08-01

    1 i OJ 1 ll CM 1 t~- VD CO OJ V* -J iv 1 a. viJ b * r-l .J" _J -^r -a- r^ a; ON 00 cn m OJ «.>. u o rH CM CO a.i (H 3 irv OT ^f pi r i...components of stress are given by the Kirsch (ref 7) equations, namely: CTrr = a (1 - a 2) + a (1 + 3a.k - 4a2) cos 20 (4) rr 2 T2" 2...G. E. Bowie, "Residual Stress by Blind-Hole Method with 0££-Center Hole," Exp. Mech., lg. No. 5, (May 1978), pp 173-179. 7. G. Kirsch , "Die Theorie

  7. Evaluation of a self-equilibrium cutting strategy for the contour method of residual stress measurement

    DOE PAGES

    Muránsky, Ondrej; Hamelin, Cory J.; Hosseinzadeh, F.; ...

    2017-04-06

    An assessment of cutting-induced plasticity (CIP) is performed, by finite element (FE) prediction of the plastic strain accumulation along the cut tip when the EDM wire sections the NeT TG4 weld benchmark specimen along two cutting directions. The first direction corresponds to a conventional (C) cutting strategy, whereby the EDM wire cuts through the thickness of the weld specimen and travels in a direction transverse to the weld. The second direction corresponds to a self-equilibrating cutting (SE) strategy, whereby the EDM wire cuts across the transverse direction of the weld specimens and travels through the thickness of the plate. Themore » cutting thus progresses simultaneously through the compression-tension-compression regions of present weld residual stress (WRS) field. This type of cutting strategy is believed to minimize the CIP by minimising residual stress redistribution during cutting, due to stress equilibration across the sectioned material. The simulated cutting procedures are conducted under a range of clamping conditions to assess whether mechanical restraint has a primary or secondary influence on CIP accumulation. Both predictions of CIP and the resultant back-calculated WRS demonstrate that (i) mechanical restraint is the primary variable influencing CIP development, and (ii) under no circumstance does a self-equilibrating cutting strategy perform significantly better than a conventional cutting approach. Furthermore, the reason that self-equilibrating cuts are not effective is illustrated by calculating the Mode I (KI) stress intensity factor (SIF) along the cut tip, and correlating trends in KI to CIP development.« less

  8. Finite Element Modeling of the Bulk Magnitization of Railroad Wheels to Improve Test Conditions for Magnetoacoustic Residual Stress Measurements

    NASA Technical Reports Server (NTRS)

    Fulton, J. P.; Wincheski, B.; Namkung, M.; Utrata, D.

    1992-01-01

    The magnetoacoustic measurement technique has been used successfully for residual stress measurements in laboratory samples. However, when used to field test samples with complex geometries, such as railroad wheels, the sensitivity of the method declines dramatically. It has been suggested that the decrease in performance may be due, in part, to an insufficient or nonuniform magnetic induction in the test sample. The purpose of this paper is to optimize the test conditions by using finite element modeling to predict the distribution of the induced bulk magnetization of railroad wheels. The results suggest that it is possible to obtain a sufficiently large and uniform bulk magnetization by altering the shape of the electromagnet used in the tests. Consequently, problems associated with bulk magnetization can be overcome, and should not prohibit the magnetoacoustic technique from being used to make residual stress measurements in railroad wheels. We begin by giving a brief overview of the magnetoacoustic technique as it applies to residual stress measurements of railroad wheels. We then define the finite element model used to predict the behavior of the current test configuration along with the nonlinear constitutive relations which we obtained experimentally through measurements on materials typically used to construct both railroad wheels and electromagnets. Finally, we show that by modifying the pole of the electromagnet it is possible to obtain a significantly more uniform bulk magnetization in the region of interest.

  9. Cavity pressure/residual stress measurements from the Non-Proliferation Experiment

    SciTech Connect

    Heinle, R.A.; Hudson, B.C.; Hatch, M.A. Jr.

    1994-12-31

    The Lawrence Livermore National Laboratory planned and conducted experiments on the Non-Proliferation Experiment to determine post-detonation gas pressure inside the explosive cavity and the residual rock stress in the region immediately outside the cavity. Before detonation there was significant concern that steam and detonation products would create very high temperatures and pressure in the blast cavity that would exist for weeks and months after firing. This could constitute a safety hazard to personnel re-entering the tunnel. Consequently the Lawrence Livermore National Laboratory was asked to field its Cavity Pressure/Residual stress monitor system on the Non-Proliferation Experiment. We obtained experimental data for the first 600 ms after the explosion and again several weeks after detonation upon tunnel re-entry. We recorded early-time cavity pressure of about 8.3 MPa. In addition we believe that the ends of our sensor hoses were subjected to an ambient driving pressure of about 0.5 MPa (absolute) that persisted until at least three weeks after zero time.

  10. X-ray measurement of near surface residual stress in textured cold-worked stress-relieved Zr 2.5%Nb pressure tube material

    NASA Astrophysics Data System (ADS)

    Kapoor, K.; Lahiri, D.; Padmaprabu, C.; Sanyal, T.

    2002-06-01

    In the present study, the near surface residual stress in Zr-2.5%Nb pressure tubes was measured using X-ray diffraction. Both cold rolled (pilgered) and stress-relieved tubes were studied. Since the material is highly textured and the hexagonal close packed crystal lattice has anisotropic elastic constants, special care is required in collection and analysis of experimental data to minimise errors. The standard multi-exposure technique of X-ray residual-stress measurement results in inaccuracies for textured material. Diffraction intensities depend on factors like inclination of the sample, the rotation of the beam and the position of detectors. Low intensity due to texture can result in increased uncertainties in observed stress value. Anisotropy of elastic constants in textured materials can further increase the errors in measured stress. A general approach has been developed for accurate determination of the stress tensor in textured material. The measured stresses for Zr-2.5%Nb pressure tubes were highest and compressive along the rolling direction (RD) in the pilgered samples. The stress-relieved samples showed a small tensile component along the RD. Errors up to 20% are introduced if isotropic elastic constants are used in the analysis instead of the more realistic anisotropic elastic constants calculated for the observed texture.

  11. Determination of calibration constants for the hole-drilling residual stress measurement technique applied to orthotropic composites. I - Theoretical considerations

    NASA Technical Reports Server (NTRS)

    Prasad, C. B.; Prabhakaran, R.; Tompkins, S.

    1987-01-01

    The hole-drilling technique for the measurement of residual stresses using electrical resistance strain gages has been widely used for isotropic materials and has been adopted by the ASTM as a standard method. For thin isotropic plates, with a hole drilled through the thickness, the idealized hole-drilling calibration constants are obtained by making use of the well-known Kirsch's solution. In this paper, an analogous attempt is made to theoretically determine the three idealized hole-drilling calibration constants for thin orthotropic materials by employing Savin's (1961) complex stress function approach.

  12. Residual stress and poisson expansion effects on the fibre-matrix interfacial properties measured in fibre push tests

    SciTech Connect

    Daniel, A.M.; Elizalde, M.R.; Martinez-Esnaola, J.M.; Janczak, J.

    1996-12-31

    There is a wide range of values reported for the interfacial frictional shear stress {tau}, in the CAS/Nicalon glass ceramic matrix composite. Depending on the test method used, {tau} can vary from less than 10MPa to over 30MPa. The fibre push-down test generally gives values in the higher portion of this range, typically {tau} {ge} 25MPa. Two models describing the push-down test, that both assume a constant {tau} along the interface, are compared with data obtained using a Nanoindentation system. One ignores any residual stresses that may be present and the other includes axial residual stresses in the fibre. The interface fracture surface energy G{sub I} was significantly lower when residual stresses were considered. The {tau} was observed to depend on the radius of fibre that was pushed, increasing as radius decreased. The effect of Poisson expansion was therefore investigated and found to contribute significantly to the {tau} recorded in these tests. It is possible that the contribution to {tau} from Poisson expansion can be more than 50% of its measured value.

  13. Confocal detection of Rayleigh scattering for residual stress measurement in chemically tempered glass

    NASA Astrophysics Data System (ADS)

    Hödemann, S.; Möls, P.; Kiisk, V.; Murata, T.; Saar, R.; Kikas, J.

    2015-12-01

    A new optical method is presented for evaluation of the stress profile in chemically tempered (chemically strengthened) glass based on confocal detection of scattered laser beam. Theoretically, a lateral resolution of 0.2 μm and a depth resolution of 0.6 μm could be achieved by using a confocal microscope with high-NA immersion objective. The stress profile in the 250 μm thick surface layer of chemically tempered lithium aluminosilicate glass was measured with a high spatial resolution to illustrate the capability of the method. The confocal method is validated using transmission photoelastic and Na+ ion concentration profile measurement. Compositional influence on the stress-optic coefficient is calculated and discussed. Our method opens up new possibilities for three-dimensional scattered light tomography of mechanical imaging in birefringent materials.

  14. Confocal detection of Rayleigh scattering for residual stress measurement in chemically tempered glass

    SciTech Connect

    Hödemann, S. Möls, P.; Kiisk, V.; Saar, R.; Kikas, J.; Murata, T.

    2015-12-28

    A new optical method is presented for evaluation of the stress profile in chemically tempered (chemically strengthened) glass based on confocal detection of scattered laser beam. Theoretically, a lateral resolution of 0.2 μm and a depth resolution of 0.6 μm could be achieved by using a confocal microscope with high-NA immersion objective. The stress profile in the 250 μm thick surface layer of chemically tempered lithium aluminosilicate glass was measured with a high spatial resolution to illustrate the capability of the method. The confocal method is validated using transmission photoelastic and Na{sup +} ion concentration profile measurement. Compositional influence on the stress-optic coefficient is calculated and discussed. Our method opens up new possibilities for three-dimensional scattered light tomography of mechanical imaging in birefringent materials.

  15. Laser sheet scattered light method for industrial measurement of thickness residual stress distribution in flat tempered glass

    NASA Astrophysics Data System (ADS)

    Castellini, P.; Stroppa, L.; Paone, N.

    2012-05-01

    The paper presents the laser sheet scattered light technique, a fast optical non contact method for measuring internal stress distribution over a cross section of flat glass specimens, designed for closed loop control of glass tempering furnaces. The technique is an evolution of the scattered light method for flat glass residual stress analysis and allows a full thickness stress profile to be measured with a single shot acquisition across a glass plate without any contact. A linearly polarized laser sheet, shaped into a thin plane of parallel light beams, enters orthogonally to the side of the flat glass illuminating its full thickness. Light sheet is orthogonal to the glass surface and travels parallel to it. Stress induced birefringence through the glass affects light polarization, thus scattered light intensity detected at 90° with respect to the polarization of the incident light appears spatially modulated in intensity. A camera aligned orthogonal to the laser light polarization collects an image of fringes whose shape is digitally analyzed to measure the thickness stress state. The paper describes the development of this technique by recalling the scattered light method, then describing its automation by scanning a collimated beam across the glass thickness and finally by showing that the scan method can be substituted by the light sheet method. Light sheet method provides a full field non contact stress measurement across the glass thickness, thus allowing for a fast inspection method, suitable for industrial use. Flat glass items for industrial use have bevelled edges; this does not allow measurements close to glass surface. To solve this limit, experimental data are extrapolated by a symmetrical polynomial fitting and imposing a zero integral to the stress profile. Results on surface stress measured by the laser sheet scattered method are in agreement with those of the automated light scattered method and show a fair agreement with measurement by an

  16. Systematic Review of Uit Parameters on Residual Stresses of Sensitized AA5456 and Field Based Residual Stress Measurements for Predicting and Mitigating Stress Corrosion Cracking

    DTIC Science & Technology

    2014-03-01

    68]. This process uses a portable, high-speed rotary tool with a series of silicon carbide ( SiC ) abrasive discs and diamond impregnated polishing...exposure technique SCC stress corrosion cracking SEOP standard and emergency operating procedures SiC silica carbide SPD severe plastic...UIT surface. Metallographic polishing was performed using silicon carbide grit papers to a 4,000 grit and diamond polishing down to a one micron

  17. The Role of Cold Work in Eddy Current Residual Stress Measurements in Shot-Peened Nickel-Base Superalloys

    NASA Astrophysics Data System (ADS)

    Yu, F.; Nagy, P. B.

    2006-03-01

    Recently, it was shown that eddy current methods can be adapted to residual stress measurement in shot-peened nickel-base superalloys. However, experimental evidence indicates that the piezoresistivity effect is simply not high enough to account for the observed apparent eddy current conductivity (AECC) increase. At the same time, X-ray diffraction data indicates that "cold work" lingers even when the residual stress is fully relaxed and the excess AECC is completely gone. It is impossible to account for both observations with a single coherent explanation unless we assume that instead of a single "cold work" effect, there are two varieties of cold work; type-A and type-B. Type-A cold work (e.g., changes in the microscopic homogeneity of the material) is not detected by X-ray diffraction as it does not significantly affect the beam width, but causes substantial conductivity change and exhibits strong thermal relaxation. Type-B cold work (e.g., dislocations) is detected by X-ray, but causes little or no conductivity change and exhibits weak thermal relaxation. Based on the assumption of two separate cold-work variables and that X-ray diffraction results indicate the presence of type-B, but not type-A, all observed phenomena can be explained. If this working hypothesis is proven right, the separation of residual stress and type-A cold work is less critical because they both relax much earlier and much faster than type-B cold work.

  18. A flexible method for residual stress measurement of spray coated layers by laser made hole drilling and SLM based beam steering

    NASA Astrophysics Data System (ADS)

    Osten, W.; Pedrini, G.; Weidmann, P.; Gadow, R.

    2015-08-01

    A minimum invasive but high resolution method for residual stress analysis of ceramic coatings made by thermal spraycoating using a pulsed laser for flexible hole drilling is described. The residual stresses are retrieved by applying the measured surface data for a model-based reconstruction procedure. While the 3D deformations and the profile of the machined area are measured with digital holography, the residual stresses are calculated by FE analysis. To improve the sensitivity of the method, a SLM is applied to control the distribution and the shape of the holes. The paper presents the complete measurement and reconstruction procedure and discusses the advantages and challenges of the new technology.

  19. Neutron-diffraction measurement of residual stresses in Al-Cu cold-cut welding

    NASA Astrophysics Data System (ADS)

    Fiori, F.; Marcantoni, M.

    Usually, when it is necessary to join different materials with a large difference in their melting points, welding should be avoided. To overcome this problem we designed and built a device to obtain cold-cut welding, which is able to strongly decrease oxidation problems of the surfaces to be welded. Thanks to this device it is possible to achieve good joining between different pairs of materials (Al-Ti, Cu-Al, Cu-Al alloys) without reaching the material melting point. The mechanical and microstructural characterisation of the joining and the validation of its quality were obtained using several experimental methods. In particular, in this work neutron-diffraction experiments for the evaluation of residual stresses in Cu-Al junctions are described, carried out at the G5.2 diffractometer of LLB, Saclay. Neutron-diffraction results are presented and related to other experimental tests such as microstructural characterisation (through optical and scanning electron microscopy) and mechanical characterisation (tensile-strength tests) of the welded interface.

  20. Axial residual stresses in boron fibers

    NASA Technical Reports Server (NTRS)

    Behrendt, D. R.

    1978-01-01

    The axial residual stress distribution as a function of radius was determined from the fiber surface to the core including the average residual stress in the core. Such measurements on boron on tungsten (B/W) fibers show that the residual stresses for 102, 142, 203, and 366 micron diameter fibers were similar, being compressive at the surface and changing monotonically to a region of tensile within the boron. At approximately 25 percent of the original radius, the stress reaches a maximum tensile stress of about 860 mn/sq.m and then decreases to a compressive stress near the tungsten boride core. Data were presented for 203 micron diameter B/W fibers that show annealing above 900 C reduces the residual stresses. A comparison between 102 micron diameter B/W and boron on carbon (b/C) shows that the residual stresses were similar in the outer regions of the fibers, but that large differences near and in the core were observed. The effects of these residual stresses on the fracture of boron fibers were discussed.

  1. Residual Stress Analysis in Thick Uranium Films

    SciTech Connect

    Hodge, A M; Foreman, R J; Gallegos, G F

    2004-12-06

    Residual stress analysis was performed on thick, 1.0 to 25 {micro}m, depleted Uranium (DU) films deposited on an Al substrate by magnetron sputtering. Two distinct characterization techniques were used to measure substrate curvature before and after deposition. Stress evaluation was performed using the Benabdi/Roche equation, which is based on beam theory of a bi-layer material. The residual stress evolution was studied as a function of coating thickness and applied negative bias voltage (0-300V). The stresses developed were always compressive; however, increasing the coating thickness and applying a bias voltage presented a trend towards more tensile stresses and thus an overall reduction of residual stresses.

  2. Residual Stresses in Ground Steels.

    DTIC Science & Technology

    1979-06-13

    stress near the surface can be lower. The level of residual stress is also strongly affected by carbon,’3 which influences the microplastic behaviour of...1966, Vol. 14, 99-104. 14. C. 3. )4cMahon: “ Microplastic Behaviour in Iron” in Mv. in Mater . S d . Res., Vol. 2, 121-140, Interscience, New York

  3. High energy X-ray diffraction measurement of residual stresses in a monolithic aluminum clad uranium–10 wt% molybdenum fuel plate assembly

    SciTech Connect

    D. W. Brown; M. A. Okuniewski; J. D. Almer; L. Balogh; B. Clausen; J. S. Okasinski; B. H. Rabin

    2013-10-01

    Residual stresses are expected in monolithic, aluminum clad uranium 10 wt% molybdenum (U–10Mo) nuclear fuel plates because of the large mismatch in thermal expansion between the two bonded materials. The full residual stress tensor of the U–10Mo foil in a fuel plate assembly was mapped with 0.1 mm resolution using high-energy (86 keV) X-ray diffraction. The in-plane stresses in the U–10Mo foil are strongly compressive, roughly -250 MPa in the longitudinal direction and -140 MPa in the transverse direction near the center of the fuel foil. The normal component of the stress is weakly compressive near the center of the foil and tensile near the corner. The disparity in the residual stress between the two in-plane directions far from the edges and the tensile normal stress suggest that plastic deformation in the aluminum cladding during fabrication by hot isostatic pressing also contributes to the residual stress field. A tensile in-plane residual stress is presumed to be present in the aluminum cladding to balance the large in-plane compressive stresses in the U–10Mo fuel foil, but cannot be directly measured with the current technique due to large grain size.

  4. PUFF TOO: a residual stress experiment

    SciTech Connect

    Smith, C.W.

    1980-04-01

    Following the passage of the dynamic effects in a contained explosive detonation, there remains a strong compressive stress field in the material about the cavity. In this experiment, a 454-kg (1000 lb) sphere of high explosive was detonated in saturated ashfall tuff. Instrumentation measured peak stresses over the range of 0.1 to 6.0 GPa (1 to 6 kbar) and the complete stress-time waveform, including the so-called residual stress, at the 0.1 GPa (1 kbar) peak stress range. Mineback revealed detonation-induced fractures and fractures induced by postevent work.

  5. Residual contact stresses in cryotechnical environments

    NASA Astrophysics Data System (ADS)

    Cretegny, J. F.; Demonicault, J. M.

    Two examples were chosen to show the use of residual stress measurements in the evaluation and comprehension of possible ruptures of parts subjected to the working conditions of cryogenic turbomachines which induce wear of the surfaces in dry contact. The examples concern the ball bearings and spline of the liquid hydrogen pump of the Vulcain engine to be used on Ariane 5. The Ariane program is introduced and tribological problems of the cryogenic technique are discussed. The utility of the residual stress measurements is assessed.

  6. Residual stresses and stress corrosion cracking in pipe fittings

    NASA Astrophysics Data System (ADS)

    Parrington, Ronald J.; Scott, James J.; Torres, Freddie

    1994-06-01

    Residual stresses can play a key role in the SCC performance of susceptible materials in PWR primary water applications. Residual stresses are stresses stored within the metal that develop during deformation and persist in the absence of external forces or temperature gradients. Sources of residual stresses in pipe fittings include fabrication processes, installation and welding. There are a number of methods to characterize the magnitude and orientation of residual stresses. These include numerical analysis, chemical cracking tests, and measurement (e.g., X-ray diffraction, neutron diffraction, strain gage/hole drilling, strain gage/trepanning, strain gage/section and layer removal, and acoustics). This paper presents 400 C steam SCC test results demonstrating that residual stresses in as-fabricated Alloy 600 pipe fittings are sufficient to induce SCC. Residual stresses present in as-fabricated pipe fittings are characterized by chemical cracking tests (stainless steel fittings tested in boiling magnesium chloride solution) and by the sectioning and layer removal (SLR) technique.

  7. RESIDUAL STRESSES IN 3013 CONTAINERS

    SciTech Connect

    Mickalonis, J.; Dunn, K.

    2009-11-10

    The DOE Complex is packaging plutonium-bearing materials for storage and eventual disposition or disposal. The materials are handled according to the DOE-STD-3013 which outlines general requirements for stabilization, packaging and long-term storage. The storage vessels for the plutonium-bearing materials are termed 3013 containers. Stress corrosion cracking has been identified as a potential container degradation mode and this work determined that the residual stresses in the containers are sufficient to support such cracking. Sections of the 3013 outer, inner, and convenience containers, in both the as-fabricated condition and the closure welded condition, were evaluated per ASTM standard G-36. The standard requires exposure to a boiling magnesium chloride solution, which is an aggressive testing solution. Tests in a less aggressive 40% calcium chloride solution were also conducted. These tests were used to reveal the relative stress corrosion cracking susceptibility of the as fabricated 3013 containers. Significant cracking was observed in all containers in areas near welds and transitions in the container diameter. Stress corrosion cracks developed in both the lid and the body of gas tungsten arc welded and laser closure welded containers. The development of stress corrosion cracks in the as-fabricated and in the closure welded container samples demonstrates that the residual stresses in the 3013 containers are sufficient to support stress corrosion cracking if the environmental conditions inside the containers do not preclude the cracking process.

  8. Residual stress characterization for laminated composites

    NASA Astrophysics Data System (ADS)

    Liu, Shao-Chun

    With increasing applications of advanced laminated composites, process-induced residual stress has drawn more and more attention in recent years. Efforts have been devoted to understanding residual stress both quantitatively and qualitatively. In the current study, a novel technique called the Cure Referencing Method was developed which has the capability for measuring the residual stress on the symmetric laminated composite plates. It can also differentiate residual stress into two components: one is due to the mismatch of the coefficient of thermal expansion, the other is caused by the matrix chemical curing shrinkage. The chemical curing shrinkage of the polymer matrix was investigated in further detail. A technique was developed to measure the post-gel chemical curing shrinkage which is the portion of curing shrinkage that really induces the residual stress in the polymer matrix composites. Time-dependent material property is another issue associated with polymer matrix composite materials. The data of several short-term tensile creep tests run at different temperature were used to construct a linear viscoelastic: model for describing the behavior of the composites over a long period of time. It was found that physical aging of the polymer matrix needs to be taken into account in order to have a more accurate representation of the long-term behavior. A fair agreement was obtained between the result of the long-term creep test and the master curve constructed from several momentary creep tests.

  9. Mechanically induced residual stresses: Modelling and characterisation

    NASA Astrophysics Data System (ADS)

    Stranart, Jean-Claude E.

    Accurate characterisation of residual stress represents a major challenge to the engineering community. This is because it is difficult to validate the measurement and the accuracy is doubtful. It is with this in mind that the current research program concerning the characterisation of mechanically induced residual stresses was undertaken. Specifically, the cold expansion of fastener holes and the shot peening treatment of aerospace alloys, aluminium 7075 and titanium Ti-6Al-4V, are considered. The objective of this study is to characterise residual stresses resulting from cold working using three powerful techniques. These are: (i) theoretical using three dimensional non-linear finite element modelling, (ii) semi-destructive using a modified incremental hole drilling technique and (iii) nondestructive using a newly developed guided wave method supplemented by traditional C-scan measurements. The three dimensional finite element results of both simultaneous and sequential cold expansion of two fastener holes revealed the importance of the separation distance, the expansion level and the loading history upon the development and growth of the plastic zone and unloading residual stresses. It further showed that the commonly adopted two dimensional finite element models are inaccurate and incapable of predicting these residual stresses. Similarly, the dynamic elasto-plastic finite element studies of shot peening showed that the depth of the compressed layer, surface and sub-surface residual stresses are significantly influenced by the shot characteristics. Furthermore, the results reveal that the separation distance between two simultaneously impacting shots governs the plastic zone development and its growth. In the semi-destructive incremental hole drilling technique, the accuracy of the newly developed calibration coefficients and measurement techniques were verified with a known stress field and the method was used to measure peening residual stresses. Unlike

  10. FEA predictions of residual stress in stainless steel compared to neutron and x-ray diffraction measurements. [Finite element analysis

    SciTech Connect

    Flower, E.C.; MacEwen, S.R.; Holden, T.M.

    1987-05-01

    Residual stresses in a body arise from nonuniform plastic deformation and continue to be an important consideration in the design and the fabrication of metal components. The finite element method offers a potentially powerful tool for predicting these stresses. However, it is important to first verify this method through careful analysis and experimentation. This paper describes experiments using neutron and x-ray diffraction to provide quantitative data to compare to finite element analysis predictions of deformation induced residual stress in a plane stress austenitic stainless steel ring. Good agreement was found between the experimental results and the numerical predictions. Effects of the formulation of the finite element model on the analysis, constitutive parameters and effects of machining damage in the experiments are addressed.

  11. Experimental measurements and influence of overload-induced residual stress field on constant amplitude fatigue crack growth in aluminum alloy

    NASA Astrophysics Data System (ADS)

    Wahab, M. A.; Rohrsheim, G. R.; Brown, I. H.

    1997-03-01

    The aim of this research is to investigate current methods in Linear Elastic Fracture Mechanics for their suitability to predict crack growth in Aluminum alloy 7050 - T7451, when a compressive residual stress field is introduced by an overload. A comparative study has been made on the effect of various levels of tensile overload on the crack growth rate in Aluminum alloy. Experiments were performed on center-cracked tension specimens at various values of range of stress- intensity-factor ((Delta) K). Crack growth measurements are performed using crack propagation gauges and a travelling microscope. The average crack growth rate is used to determine an effective (Delta) K value for each interval using the fatigue crack propagation curve. After the application of overloads, the propagation gauges revealed a period of significant retardation before the crack growth rates returned to their baseline levels. The results from the numerical predictions are compared with the experimental results. The prediction model produces conservative results for both constant amplitude crack growth and overload induced retarded growth.

  12. Anomalies in X-Ray Residual Stress Measurements in Cold-Rolled Steels

    DTIC Science & Technology

    1979-09-07

    and A s2 (hkl) as follows: (21 ) rll( hkj ) - r 2 2 (hkl) = sl(hkL) [1a] r 33 (hkA) = Sl( hkj ) + J s2 ( hkj ) [7b] rl2 (hkA) = rl3 (hkL) = r23 (hkt) = 0 𔄁c...the axes of the specimen, Pi. and the natural axes of the texture Bj. 2. An hkj reflection is chosen to be measured. 3. All planes in its form and the...utilize measured values of the elastic caistants sl(hkL) and I s2( hkj ). From Eq. 11 it is clear that these values can be obtained by elastically loading

  13. THE CONTOUR METHOD: SIMPLE 2-D MAPPING OF RESIDUAL STRESSES

    SciTech Connect

    M. PRIME; A. GONZALES

    2000-06-01

    We present an entirely new method for measuring residual stress that is extremely simple to apply yet more powerful than existing techniques. In this method, a part is carefully cut in two. The contour of the resulting new surface is measured to determine the displacements normal to the surface caused by the release of the residual stresses. Analytically, the opposite of these measured displacements are applied as boundary conditions to the surface in a finite element model. By Bueckner's superposition principle, this gives the original residual stresses normal to the plane of the cut. Unlike other relaxation methods for measuring residual stress, the measured data can be used to solve directly for the stresses without a tedious inversion technique. At the same time, an arbitrary two-dimensional variation in stresses can be determined. We demonstrate the method on a steel specimen with a known residual stress profile.

  14. Thermal residual stresses near the interface between plasma-sprayed hydroxyapatite coating and titanium substrate: finite element analysis and synchrotron radiation measurements.

    PubMed

    Cofino, B; Fogarassy, P; Millet, P; Lodini, A

    2004-07-01

    Plasma-sprayed hydroxyapatite (HA) coatings on titanium alloy are often used in prosthetic implants. The metallic substrate gives the implant good mechanical strength which is combined with good biocompatibility and osteointegration of the ceramic coating. However, the interface between the HA coating and titanium alloy substrate is an area of critical weakness when compared with the interlamellar cohesive strength of the HA coating structure. Knowledge of the stresses in materials near the interface seems to be an important step in understanding why failure occurs. Synchrotron radiation, using Beamline BM16 at the European Synchrotron Radiation Facility (Grenoble, France), has been used to determine local stresses near the interface, down to 10 microm in resolution, between a plasma-sprayed HA coating and a titanium alloy substrate. This experimental determination of residual stresses is compared with the results found by a finite element analysis modeling the thermal effects of the plasma-spraying process. Residual stresses have been found in deposited ceramic near the interface due to a thermal properties mismatch of the materials. If the plane stress state is assumed, meaning the perpendicular component of residual stress is ignored (sigma(z) = 0), then the synchrotron residual stress measurements should be interpreted as mainly compressive in the ceramic coating. This is in contradiction with the coefficient of thermal expansion mismatch; therefore, the simplified plane stresses assumption seems to be inappropriate for the deposited morphology characterized by pores and a network of microcracks. The detailed finite element analysis model, taking into account the real morphology of the coating and the real three-dimensional stress field distribution, allowed the estimation of sigma(z), leading to a more accurate interpretation of synchrotron measurements, which is validated by the experimental results.

  15. Nanohardness and Residual Stress in TiN Coatings

    PubMed Central

    Hernández, Luis Carlos; Ponce, Luis; Fundora, Abel; López, Enrique; Pérez, Eduardo

    2011-01-01

    TiN films were prepared by the Cathodic arc evaporation deposition method under different negative substrate bias. AFM image analyses show that the growth mode of biased coatings changes from 3D island to lateral when the negative bias potential is increased. Nanohardness of the thin films was measured by nanoindentation, and residual stress was determined using Grazing incidence X ray diffraction. The maximum value of residual stress is reached at −100 V substrate bias coinciding with the biggest values of adhesion and nanohardness. Nanoindentation measurement proves that the force-depth curve shifts due to residual stress. The experimental results demonstrate that nanohardness is seriously affected by the residual stress.

  16. Residual Stress Analysis Based on Acoustic and Optical Methods

    PubMed Central

    Yoshida, Sanichiro; Sasaki, Tomohiro; Usui, Masaru; Sakamoto, Shuichi; Gurney, David; Park, Ik-Keun

    2016-01-01

    Co-application of acoustoelasticity and optical interferometry to residual stress analysis is discussed. The underlying idea is to combine the advantages of both methods. Acoustoelasticity is capable of evaluating a residual stress absolutely but it is a single point measurement. Optical interferometry is able to measure deformation yielding two-dimensional, full-field data, but it is not suitable for absolute evaluation of residual stresses. By theoretically relating the deformation data to residual stresses, and calibrating it with absolute residual stress evaluated at a reference point, it is possible to measure residual stresses quantitatively, nondestructively and two-dimensionally. The feasibility of the idea has been tested with a butt-jointed dissimilar plate specimen. A steel plate 18.5 mm wide, 50 mm long and 3.37 mm thick is braze-jointed to a cemented carbide plate of the same dimension along the 18.5 mm-side. Acoustoelasticity evaluates the elastic modulus at reference points via acoustic velocity measurement. A tensile load is applied to the specimen at a constant pulling rate in a stress range substantially lower than the yield stress. Optical interferometry measures the resulting acceleration field. Based on the theory of harmonic oscillation, the acceleration field is correlated to compressive and tensile residual stresses qualitatively. The acoustic and optical results show reasonable agreement in the compressive and tensile residual stresses, indicating the feasibility of the idea. PMID:28787912

  17. Grinding Induced Changes in Residual Stresses of Carburized Gears

    SciTech Connect

    Lemaster, Robert A; Boggs, Bryan L; Bunn, Jeffrey R; Hubbard, Camden R; Watkins, Thomas R

    2009-01-01

    This paper presents the results of a study performed to measure the change in residual stress that results from the finish grinding of carburized gears. Residual stresses were measured in five gears using the x-ray diffraction equipment in the Large Specimen Residual Stress Facility at Oak Ridge National Laboratory. Two of the gears were hobbed, carburized, quenched and tempered, but not finished. The remaining three gears were processed similarly, but were finish ground. The residual stresses were measured at 64 different locations on a tooth from each gear. Residual stresses were also measured at fewer points on other teeth to determine the tooth-to-tooth variation. Tooth profile measurements were made of the finished and unfinished gear samples. The results show a fairly uniform and constant compressive residual field in the nonfinished gears. There was a significant reduction in the average residual stress measured in the finished gears. Additionally, there was a significant increase in the variability of the residual stress that was introduced by the grinding process. Analysis of the data suggests a linear relationship between the change in average residual stress and the amount of material removed by the grinding process.

  18. Quantifying Residual Stresses by Means of Thermoelastic Stress Analysis

    NASA Technical Reports Server (NTRS)

    Gyekenyesi, Andrew L.; Baaklini, George Y.

    2001-01-01

    This study focused on the application of the Thermoelastic Stress Analysis (TSA) technique as a tool for assessing the residual stress state of structures. TSA is based on the fact that materials experience small temperature changes when compressed or expanded. When a structure is cyclically loaded, a surface temperature profile results which correlates to the surface stresses. The cyclic surface temperature is measured with an infrared camera. Traditionally, the amplitude of a TSA signal was theoretically defined to be linearly dependent on the cyclic stress amplitude. Recent studies have established that the temperature response is also dependent on the cyclic mean stress (i.e., the static stress state of the structure). In a previous study by the authors, it was shown that mean stresses significantly influenced the TSA results for titanium- and nickel-based alloys. This study continued the effort of accurate direct measurements of the mean stress effect by implementing various experimental modifications. In addition, a more in-depth analysis was conducted which involved analyzing the second harmonic of the temperature response. By obtaining the amplitudes of the first and second harmonics, the stress amplitude and the mean stress at a given point on a structure subjected to a cyclic load can be simultaneously obtained. The experimental results showed good agreement with the theoretical predictions for both the first and second harmonics of the temperature response. As a result, confidence was achieved concerning the ability to simultaneously obtain values for the static stress state as well as the cyclic stress amplitude of structures subjected to cyclic loads using the TSA technique. With continued research, it is now feasible to establish a protocol that would enable the monitoring of residual stresses in structures utilizing TSA.

  19. Residual stress and crack propagation in laminated composites

    SciTech Connect

    Yttergren, R.M.F.; Zeng, K.; Rowcliffe, D.J.

    1994-12-31

    Residual stress distributions in several laminated ceramic composites were measured by an indentation technique. The material included alumina-zirconia laminated composites, containing strong interfaces, and alumina-porcelain laminated composites with both weak and strong interfaces. The residual stress in these material originates from the mismatch of the thermal properties, differences in elastic properties, and different shrinkage of the laminates during sintering. An experimental technique is presented which gives a direct view of the residual stress state in the materials. Values of residual tensile stress are presented as a function of position relative to the interface in each material.

  20. Blocks and residual stresses in shaped sapphire single crystals

    NASA Astrophysics Data System (ADS)

    Krymov, V. M.; Nosov, Yu. G.; Bakholdin, S. I.; Maslov, V. N.; Shul‧pina, I. L.; Nikolaev, V. I.

    2017-01-01

    The formation of blocks and residual stresses in shaped sapphire crystals grown from the melt by the Stepanov method (EFG) has been studied. The probability of block formation is higher for the growth along the c axis compared to that grown in the a-axis direction. The distribution of residual stress in sapphire crystals of tubular, rectangular and round cross section was measured by the conoscopy method. It was found that the magnitude of the residual stress increases from the center to the periphery of the crystal and reaches up to about 20 MPa. Residual stress tensor components for solid round rod and tubular single crystals were determined by numerical integration.

  1. X-Ray Diffraction Residual Stress Analysis: One of the Few Advanced Physical Measuring Techniques That Have Established Themselves for Routine Application in Industry

    NASA Astrophysics Data System (ADS)

    Nierlich, Wolfgang; Gegner, Jürgen

    The conventional procedure of X-ray diffraction (XRD) residual stress measurement is improved by means of a modification of the beam path of the diffractometer and an iterative technique that includes a pre-analysis of the nearpeak line-profile. The achieved short measuring times of 5 and around 10 min per residual stress value and retained austenite content, respectively, serve as precondition for routine industrial applications over the last three decades within SKF. The line width represents a measure of material ageing within the lifetime cycle of a rolling bearing: calibration curves for the (near-) surface and the sub-surface failure mode are presented. Material response analysis permits differentiation of these failure modes and between low- and high-cycle fatigue.

  2. Residual stresses in polymer matrix composite laminates

    NASA Technical Reports Server (NTRS)

    Hahn, H. T.

    1976-01-01

    Residual stresses in composites are induced during fabrication and by environmental exposure. The theory formulated can describe the shrinkage commonly observed after a thermal expansion test. Comparison between the analysis and experimental data for laminates of various material systems indicates that the residual stress-free temperature can be lower than the curing temperature, depending on the curing process. Effects of residual stresses on ply failure including the acoustic emission characteristics are discussed.

  3. Lamination residual stresses in fiber composites

    NASA Technical Reports Server (NTRS)

    Daniel, I. M.; Liber, T.

    1975-01-01

    An experimental investigation was conducted to determine the magnitude of lamination residual stresses in angle-ply composites and to evaluate their effects on composite structural integrity. The materials investigated were boron/epoxy, boron/polyimide, graphite/low modulus epoxy, graphite/high modulus epoxy, graphite/polyimide and s-glass/epoxy. These materials were fully characterized. Static properties of laminates were also determined. Experimental techniques using embedded strain gages were developed and used to measure residual strains during curing. The extent of relaxation of lamination residual stresses was investigated. It was concluded that the degree of such relaxation is low. The behavior of angle-ply laminates subjected to thermal cycling, tensile load cycling, and combined thermal cycling with tensile load was investigated. In most cases these cycling programs did not have any measurable influence on residual strength and stiffness of the laminates. In the tensile load cycling tests, the graphite/polyimide shows the highest endurance with 10 million cycle runouts at loads up to 90 percent of the static strength.

  4. Measurement of Young’s modulus and residual stress of atomic layer deposited Al2O3 and Pt thin films

    NASA Astrophysics Data System (ADS)

    Purkl, Fabian; Daus, Alwin; English, Timothy S.; Provine, J.; Feyh, Ando; Urban, Gerald; Kenny, Thomas W.

    2017-08-01

    The accurate measurement of mechanical properties of thin films is required for the design of reliable nano/micro-electromechanical devices but is increasingly challenging for thicknesses approaching a few nanometers. We apply a combination of resonant and static mechanical test structures to measure elastic constants and residual stresses of 8-27 nm thick Al2O3 and Pt layers which have been fabricated through atomic layer deposition. Young’s modulus of poly-crystalline Pt films was found to be reduced by less than 15% compared to the bulk value, whereas for amorphous Al2O3 it was reduced to about half of its bulk value. We observed no discernible dependence of the elastic constant on thickness or deposition method for Pt, but the use of plasma-enhanced atomic layer deposition was found to increase Young’s modulus of Al2O3 by 10% compared to a thermal atomic layer deposition. As deposited, the Al2O3 layers had an average tensile residual stress of 131 MPa. The stress was found to be higher for thinner layers and layers deposited without the help of a remote plasma. No residual stress values could be extracted for Pt due to insufficient adhesion of the film without an underlying layer to promote nucleation.

  5. A finite element model for residual stress in repair welds

    SciTech Connect

    Feng, Z.; Wang, X.L.; Spooner, S.; Goodwin, G.M.; Maziasz, P.J.; Hubbard, C.R.; Zacharia, T.

    1996-03-28

    This paper describes a three-dimensional finite element model for calculation of the residual stress distribution caused by repair welding. Special user subroutines were developed to simulate the continuous deposition of filler metal during welding. The model was then tested by simulating the residual stress/strain field of a FeAl weld overlay clad on a 2{1/4}Cr-1 Mo steel plate, for which neutron diffraction measurement data of the residual strain field were available. It is shown that the calculated residual stress distribution was consistent with that determined with neutron diffraction. High tensile residual stresses in both the longitudinal and transverse directions were observed around the weld toe at the end of the weld. The strong spatial dependency of the residual stresses in the region around the weld demonstrates that the common two-dimensional cross-section finite element models should not be used for repair welding analysis.

  6. A synchrotron X-ray diffraction deconvolution method for the measurement of residual stress in thermal barrier coatings as a function of depth.

    PubMed

    Li, C; Jacques, S D M; Chen, Y; Daisenberger, D; Xiao, P; Markocsan, N; Nylen, P; Cernik, R J

    2016-12-01

    The average residual stress distribution as a function of depth in an air plasma-sprayed yttria stabilized zirconia top coat used in thermal barrier coating (TBC) systems was measured using synchrotron radiation X-ray diffraction in reflection geometry on station I15 at Diamond Light Source, UK, employing a series of incidence angles. The stress values were calculated from data deconvoluted from diffraction patterns collected at increasing depths. The stress was found to be compressive through the thickness of the TBC and a fluctuation in the trend of the stress profile was indicated in some samples. Typically this fluctuation was observed to increase from the surface to the middle of the coating, decrease a little and then increase again towards the interface. The stress at the interface region was observed to be around 300 MPa, which agrees well with the reported values. The trend of the observed residual stress was found to be related to the crack distribution in the samples, in particular a large crack propagating from the middle of the coating. The method shows promise for the development of a nondestructive test for as-manufactured samples.

  7. A synchrotron X-ray diffraction deconvolution method for the measurement of residual stress in thermal barrier coatings as a function of depth

    PubMed Central

    Li, C.; Jacques, S. D. M.; Chen, Y.; Daisenberger, D.; Xiao, P.; Markocsan, N.; Nylen, P.; Cernik, R. J.

    2016-01-01

    The average residual stress distribution as a function of depth in an air plasma-sprayed yttria stabilized zirconia top coat used in thermal barrier coating (TBC) systems was measured using synchrotron radiation X-ray diffraction in reflection geometry on station I15 at Diamond Light Source, UK, employing a series of incidence angles. The stress values were calculated from data deconvoluted from diffraction patterns collected at increasing depths. The stress was found to be compressive through the thickness of the TBC and a fluctuation in the trend of the stress profile was indicated in some samples. Typically this fluctuation was observed to increase from the surface to the middle of the coating, decrease a little and then increase again towards the interface. The stress at the interface region was observed to be around 300 MPa, which agrees well with the reported values. The trend of the observed residual stress was found to be related to the crack distribution in the samples, in particular a large crack propagating from the middle of the coating. The method shows promise for the development of a nondestructive test for as-manufactured samples. PMID:27980507

  8. Neutron diffraction measurement of residual stresses, dislocation density and texture in Zr-bonded U-10Mo “mini” fuel foils and plates

    SciTech Connect

    Brown, Donald William; Okuniewski, Maria A.; Sisneros, Thomas A.; Clausen, Bjorn; Moore, Glenn A.; Balogh, Levente

    2016-12-01

    Here, Al clad U-10Mo fuel plates are being considered for conversion of several research reactors from high-enriched to low-enriched U fuel. Neutron diffraction measurements of the textures, residual phase stresses, and dislocation densities in the individual phases of the mini-foils throughout several processing steps and following hot-isostatic pressing to the Al cladding, have been completed. Recovery and recrystallization of the bare U-10Mo fuel foil, as indicated by the dislocation density and texture, are observed depending on the state of the material prior to annealing and the duration and temperature of the annealing process. In general, the cladding procedure significantly reduces the dislocation density, but the final state of the clad plate, both texture and dislocation density, depends strongly on the final processing step of the fuel foil. In contrast, the residual stress state of the final plate is dominated by the thermal expansion mismatch of the constituent materials.

  9. Neutron diffraction measurement of residual stresses, dislocation density and texture in Zr-bonded U-10Mo "mini" fuel foils and plates

    NASA Astrophysics Data System (ADS)

    Brown, D. W.; Okuniewski, M. A.; Sisneros, T. A.; Clausen, B.; Moore, G. A.; Balogh, L.

    2016-12-01

    Al clad U-10Mo fuel plates are being considered for conversion of several research reactors from high-enriched to low-enriched U fuel. Neutron diffraction measurements of the textures, residual phase stresses, and dislocation densities in the individual phases of the mini-foils throughout several processing steps and following hot-isostatic pressing to the Al cladding, have been completed. Recovery and recrystallization of the bare U-10Mo fuel foil, as indicated by the dislocation density and texture, are observed depending on the state of the material prior to annealing and the duration and temperature of the annealing process. In general, the cladding procedure significantly reduces the dislocation density, but the final state of the clad plate, both texture and dislocation density, depends strongly on the final processing step of the fuel foil. In contrast, the residual stress state of the final plate is dominated by the thermal expansion mismatch of the constituent materials.

  10. Residual stresses and vector hysteresis modeling

    NASA Astrophysics Data System (ADS)

    Ktena, Aphrodite

    2016-04-01

    Residual stresses in magnetic materials, whether the result of processing or intentional loading, leave their footprint on macroscopic data, such hysteresis loops and differential permeability measurements. A Preisach-type vector model is used to reproduce the phenomenology observed based on assumptions deduced from the data: internal stresses lead to smaller and misaligned grains, hence increased domain wall pinning and angular dispersion of local easy axes, favouring rotation as a magnetization reversal mechanism; misaligned grains contribute to magnetostatic fields opposing the direction of the applied field. The model is using a vector operator which accounts for both reversible and irreversible processes; the Preisach concept for interactions for the role of stress related demagnetizing fields; and a characteristic probability density function which is constructed as a weighed sum of constituent functions: the material is modeled as consisting of various subsystems, e.g. reversal mechanisms or areas subject to strong/weak long range interactions and each subsystem is represented by a constituent probability density function. Our assumptions are validated since the model reproduces the hysteresis loops and differential permeability curves observed experimentally and calculations involving rotating inputs at various residual stress levels are consistent and in agreement with experimental evidence.

  11. Residual stress in spin-cast polyurethane thin films

    SciTech Connect

    Zhang, Hong; Zhang, Li

    2015-01-19

    Residual stress is inevitable during spin-casting. Herein, we report a straightforward method to evaluate the residual stress in as-cast polyurethane thin films using area shrinkage measurement of films in floating state, which shows that the residual stress is independent of radial location on the substrate and decreased with decreasing film thickness below a critical value. We demonstrate that the residual stress is developed due to the solvent evaporation after vitrification during spin-casting and the polymer chains in thin films may undergo vitrification at an increased concentration. The buildup of residual stress in spin-cast polymer films provides an insight into the size effects on the nature of polymer thin films.

  12. Neutron Diffraction Measurement of Residual Stresses, Dislocation Density and Texture in Zr-bonded U-10Mo ''Mini'' Fuel Foils and Plates

    SciTech Connect

    Brown, Donald W.; Okuniewski, M. A.; Sisneros, Thomas A.; Clausen, Bjorn; Moore, G. A.; Balogh, L

    2014-08-07

    Aluminum clad monolithic uranium 10 weight percent molybdenum (U-10Mo) fuel plates are being considered for conversion of several research and test nuclear reactors from high-enriched to low-enriched uranium fuel due to the inherently high density of fissile material. Comprehensive neutron diffraction measurements of the evolution of the textures, residual phase stresses, and dislocation densities in the individual phases of the mini-foils throughout several processing steps and following hot-isostatic pressing to the Al cladding, have been completed. Recovery and recrystallization of the bare U-10Mo fuel foil, as indicated by the dislocation density and texture, are observed depending on the state of the material prior to annealing and the duration and temperature of the annealing process. In general, the HIP procedure significantly reduces the dislocation density, but the final state of the clad plate, both texture and dislocation density, depends strongly on the final processing step of the fuel foil. In contrast, the residual stresses in the clad fuel plate do not depend strongly on the final processing step of the bare foil prior to HIP bonding. Rather, the residual stresses are dominated by the thermal expansion mismatch of the constituent materials of the fuel plate.

  13. Creep Deformation, Rupture Analysis, Heat Treatment and Residual Stress Measurement of Monolithic and Welded Grade 91 Steel for Power Plant Components

    NASA Astrophysics Data System (ADS)

    Shrestha, Triratna

    Modified 9Cr-1 Mo (Grade 91) steel is currently considered as a candidate material for reactor pressure vessels (RPVs) and reactor internals for the Very High Temperature Reactor (VHTR), and in fossil-fuel fired power plants at higher temperatures and stresses. The tensile creep behavior of Grade 91 steel was studied in the temperature range of 600°C to 750°C and stresses between 35 MPa and 350 MPa. Heat treatment of Grade 91 steel was studied by normalizing and tempering the steel at various temperatures and times. Moreover, Thermo-Ca1c(TM) calculation was used to predict the precipitate stability and their evolution, and construct carbon isopleths of Grade 91 steel. Residual stress distribution across gas tungsten arc welds (GTAW) in Grade 91 steel was measured by the time-of-flight neutron diffraction using the Spectrometer for Materials Research at Temperature and Stress (SMARTS) diffractometer at Lujan Neutron Scattering Center, Los Alamos National Laboratory, Los Alamos, NM, USA. Analysis of creep results yielded stress exponents of ˜9-11 in the higher stress regime and ˜1 in the lower stress regime. The creep behavior of Grade 91 steel was described by the modified Bird-Mukherjee-Dorn relation. The rate-controlling creep deformation mechanism in the high stress regime was identified as the edge dislocation climb with a stress exponent of n = 5. On the other hand, the deformation mechanism in the Newtonian viscous creep regime (n = 1) was identified as the Nabarro-Herring creep. Creep rupture data were analyzed in terms of Monkman-Grant relation and Larson-Miller parameter. Creep damage tolerance factor and stress exponent were used to identify the cause of creep damage. The fracture surface morphology of the ruptured specimens was studied by scanning electron microscopy to elucidate the failure mechanisms. Fracture mechanism map for Grade 91 steel was developed based on the available material parameters and experimental observations. The microstructural

  14. Prediction of machining induced residual stresses

    NASA Astrophysics Data System (ADS)

    Pramod, Monangi; Reddy, Yarkareddy Gopi; Prakash Marimuthu, K.

    2017-07-01

    Whenever a component is machined, residual stresses are induced in it. These residual stresses induced in the component reduce its fatigue life, corrosion resistance and wear resistance. Thus it is important to predict and control the machining-induced residual stress. A lot of research is being carried out in this area in the past decade. This paper aims at prediction of residual stresses during machining of Ti-6Al-4V. A model was developed and under various combinations of cutting conditions such as, speed, feed and depth of cut, the behavior of residual stresses were simulated using Finite Element Model. The present work deals with the development of thermo-mechanical model to predict the machining induced residual stresses in Titanium alloy. The simulation results are compared with the published results. The results are in good agreement with the published results. Future work involves optimization or the cutting parameters that effect the machining induced residual stresses. The results obtained were validated with previous work.

  15. Method For Characterizing Residual Stress In Metals

    DOEpatents

    Jacobson, Loren A.; Michel, David J.; Wyatt, Jeffrey R.

    2002-12-03

    A method is provided for measuring the residual stress in metals. The method includes the steps of drilling one or more holes in a metal workpiece to a preselected depth and mounting one or more acoustic sensors on the metal workpiece and connecting the sensors to an electronic detecting and recording device. A liquid metal capable of penetrating into the metal workpiece placed at the bottom of the hole or holes. A recording is made over a period of time (typically within about two hours) of the magnitude and number of noise events which occur as the liquid metal penetrates into the metal workpiece. The magnitude and number of noise events are then correlated to the internal stress in the region of the workpiece at the bottom of the hole.

  16. Relating Residual Stress and Substructural Evolution During Tensile Deformation of an Aluminum-Manganese Alloy

    NASA Astrophysics Data System (ADS)

    Lodh, Arijit; Tak, Tawqeer Nasir; Prakash, Aditya; Guruprasad, P. J.; Hutchinson, Christopher; Samajdar, Indradev

    2017-08-01

    Interrupted tensile tests were coupled with ex situ measurements of residual stress and microtexture. The residual stress quantification involved measurements of six independent Laue spots and conversion of the interplanar spacings to the residual stress tensor. A clear orientation-dependent residual stress evolution emerged from the experiments and the numerical simulations. For the orientations undergoing negligible changes in ρ GND (density of geometrically necessary dislocation), the residual stress developments appeared to be governed by the elastic stiffness of the grain clusters. For the others, the evolution of the residual stress and ρ GND exhibited a clear orientation-dependent scaling.

  17. Residual stress effects in stress-corrosion cracking

    NASA Astrophysics Data System (ADS)

    Toribio, J.

    1998-04-01

    This paper describes a wide variety of residual stress effects in stress-corrosion cracking (SCC) of metallic materials on the basis of previous research of the author on high-strength steel in the form of hot-rolled bars and cold-drawn wires for prestressed concrete. It is seen that internal residual stress fields in the material play a very important—if not decisive—role in the SCC behavior of any engineering material, especially residual stresses generated near the free surface or in the vicinity of a crack tip.

  18. Residual stress effects in stress-corrosion cracking

    SciTech Connect

    Toribio, J.

    1998-04-01

    This paper describes a wide variety of residual stress effects in stress-corrosion cracking (SCC) of metallic materials on the basis of previous research of the author on high-strength steel in the form of hot-rolled bars and cold-drawn wires for prestressed concrete. It is seen that internal residual stress fields in the material play a very important -- if not decisive -- role in the SCC behavior of any engineering material, especially residual stresses generated near the free surface or in the vicinity of a crack tip.

  19. Evaluation of Surface Residual Stresses in Friction Stir Welds Due to Laser and Shot Peening

    NASA Technical Reports Server (NTRS)

    Hatamleh, Omar; Rivero, Iris V.; Lyons, Jed

    2007-01-01

    The effects of laser, and shot peening on the residual stresses in Friction Stir Welds (FSW) has been investigated. The surface residual stresses were measured at five different locations across the weld in order to produce an adequate residual stress profile. The residual stresses before and after sectioning the coupon from the welded plate were also measured, and the effect of coupon size on the residual stress relaxation was determined and characterized. Measurements indicate that residual stresses were not uniform along the welded plate, and large variation in stress magnitude could be exhibited at various locations along the FSW plate. Sectioning resulted in significant residual stress relaxation in the longitudinal direction attributed to the large change in dimensions in this direction. Overall, Laser and shot peening resulted in a significant reduction in tensile residual stresses at the surface of the specimens.

  20. Neutron diffractometer RSND for residual stress analysis at CAEP

    NASA Astrophysics Data System (ADS)

    Li, Jian; Wang, Hong; Sun, Guangai; Chen, Bo; Chen, Yanzhou; Pang, Beibei; Zhang, Ying; Wang, Yun; Zhang, Changsheng; Gong, Jian; Liu, Yaoguang

    2015-05-01

    Residual Stress Neutron Diffractometer (RSND) has been built at China Academy of Engineering Physics (CAEP) in Mianyang. Due to its excellent flexibility, the residual stress measurement on different samples, as well as in-situ study for materials science, can be carried out through RSND. The basic tests on its intensity and resolution and some preliminary experimental results under mechanical load, demonstrate the high quality of RSND.

  1. Water aging reverses residual stresses in hydrophilic dental composites.

    PubMed

    Park, J W; Ferracane, J L

    2014-02-01

    Dental composites develop residual stresses during polymerization due to shrinkage. These stresses may change with time because of relaxation and water sorption in the oral environment. This phenomenon is likely dependent on the composition of the materials, specifically their hydrophilic characteristics, and could result in deleterious stresses on restorative materials and tooth structure. The purpose of this experiment was to use the thin ring-slitting method to compare the residual stress generated within composite materials of varying hydrophilicity when aged in wet and dry conditions after polymerization. Water sorption, solubility, elastic modulus, and residual stresses were measured in 6 commercial composites/cements aged in water and dry conditions. The self-adhesive resin cement showed the highest water sorption and solubility. All composites showed initial residual contraction stresses, which were maintained when aged dry. Residual stresses in 2 of the self-adhesive cements and the polyacid-modified composite aged in wet conditions resulted in a net expansion. This experiment verified that residual shrinkage stresses in dental composites can be reversed during aging in water, resulting in a net expansion, with the effect directly related to their hydrophilic properties.

  2. Residual Stress Testing of Outer 3013 Containers

    SciTech Connect

    Dunn, K.

    2004-02-12

    A Gas Tungsten Arc Welded (GTAW) outer 3013 container and a laser welded outer 3013 container have been tested for residual stresses according to the American Society for Testing Materials (ASTM) Standard G-36-94 [1]. This ASTM standard describes a procedure for conducting stress-corrosion cracking tests in boiling magnesium chloride (MgCl2) solution. Container sections in both the as-fabricated condition as well as the closure welded condition were evaluated. Significantly large residual stresses were observed in the bottom half of the as-fabricated container, a result of the base to can fabrication weld because through wall cracks were observed perpendicular to the weld. This observation indicates that regardless of the closure weld technique, sufficient residual stresses exist in the as-fabricated container to provide the stress necessary for stress corrosion cracking of the container, at the base fabrication weld. Additionally, sufficiently high residual stresses were observed in both the lid and the body of the GTAW as well as the laser closure welded containers. The stresses are oriented perpendicular to the closure weld in both the container lid and the container body. Although the boiling MgCl2 test is not a quantitative test, a comparison of the test results from the closure welds shows that there are noticeably more through wall cracks in the laser closure welded container than in the GTAW closure welded container.

  3. Residual stress in glass: indentation crack and fractography approaches.

    PubMed

    Anunmana, Chuchai; Anusavice, Kenneth J; Mecholsky, John J

    2009-11-01

    To test the hypothesis that the indentation crack technique can determine surface residual stresses that are not statistically significantly different from those determined from the analytical procedure using surface cracks, the four-point flexure test, and fracture surface analysis. Soda-lime-silica glass bar specimens (4 mm x 2.3 mm x 28 mm) were prepared and annealed at 650 degrees C for 30 min before testing. The fracture toughness values of the glass bars were determined from 12 specimens based on induced surface cracks, four-point flexure, and fractographic analysis. To determine the residual stress from the indentation technique, 18 specimens were indented under 19.6N load using a Vickers microhardness indenter. Crack lengths were measured within 1 min and 24h after indentation, and the measured crack lengths were compared with the mean crack lengths of annealed specimens. Residual stress was calculated from an equation developed for the indentation technique. All specimens were fractured in a four-point flexure fixture and the residual stress was calculated from the strength and measured crack sizes on the fracture surfaces. The results show that there was no significant difference between the residual stresses calculated from the two techniques. However, the differences in mean residual stresses calculated within 1 min compared with those calculated after 24h were statistically significant (p=0.003). This study compared the indentation technique with the fractographic analysis method for determining the residual stress in the surface of soda-lime-silica glass. The indentation method may be useful for estimating residual stress in glass.

  4. Residual stress in glass: indentation crack and fractography approaches

    PubMed Central

    Anunmana, Chuchai; Anusavice, Kenneth J.; Mecholsky, John J.

    2009-01-01

    Objective To test the hypothesis that the indentation crack technique can determine surface residual stresses that are not statistically significantly different from those determined from the analytical procedure using surface cracks, the four-point flexure test, and fracture surface analysis. Methods Soda-lime-silica glass bar specimens (4 mm × 2.3 mm × 28 mm) were prepared and annealed at 650 °C for 30 min before testing. The fracture toughness values of the glass bars were determined from 12 specimens based on induced surface cracks, four-point flexure, and fractographic analysis. To determine the residual stress from the indentation technique, 18 specimens were indented under 19.6 N load using a Vickers microhardness indenter. Crack lengths were measured within 1 min and 24 h after indentation, and the measured crack lengths were compared with the mean crack lengths of annealed specimens. Residual stress was calculated from an equation developed for the indentation technique. All specimens were fractured in a four-point flexure fixture and the residual stress was calculated from the strength and measured crack sizes on the fracture surfaces. Results The results show that there was no significant difference between the residual stresses calculated from the two techniques. However, the differences in mean residual stresses calculated within 1 min compared with those calculated after 24 h were statistically significant (p=0.003). Significance This study compared the indentation technique with the fractographic analysis method for determining the residual stress in the surface of soda-lime silica glass. The indentation method may be useful for estimating residual stress in glass. PMID:19671475

  5. Prediction of residual stress and distortion from residual stress in heat treated and machined aluminum parts

    NASA Astrophysics Data System (ADS)

    Jones, Robert

    Parts machined from relatively large thickness cross sections can experience significant deformations from high residual stresses that develop in the part during the heat treatment used to form the aluminum alloy. Uphill quenching is a process that can create a part with low residual stress and stable dimensions when the process is controlled properly. The uphill quenching process involves a solution heat treat, quench, cool to liquid nitrogen, steam blast, and then age to final temper. In this thesis two parts were modeled using ANSYS. The first part underwent the uphill quench process in the rough machined state. The second part was modeled in the stock material shape and only underwent a solution heat treat, quench, and age to final temper. After the residual stress in the second part was predicted the excess material was removed by killing the associated elements and the deformation of the final machined part was predicted. For both parts analyzed measurements were made and compared against predictions with fairly good results.

  6. Neutron diffraction measurement of residual stresses, dislocation density and texture in Zr-bonded U-10Mo “mini” fuel foils and plates

    DOE PAGES

    Brown, Donald William; Okuniewski, Maria A.; Sisneros, Thomas A.; ...

    2016-12-01

    Here, Al clad U-10Mo fuel plates are being considered for conversion of several research reactors from high-enriched to low-enriched U fuel. Neutron diffraction measurements of the textures, residual phase stresses, and dislocation densities in the individual phases of the mini-foils throughout several processing steps and following hot-isostatic pressing to the Al cladding, have been completed. Recovery and recrystallization of the bare U-10Mo fuel foil, as indicated by the dislocation density and texture, are observed depending on the state of the material prior to annealing and the duration and temperature of the annealing process. In general, the cladding procedure significantly reducesmore » the dislocation density, but the final state of the clad plate, both texture and dislocation density, depends strongly on the final processing step of the fuel foil. In contrast, the residual stress state of the final plate is dominated by the thermal expansion mismatch of the constituent materials.« less

  7. Neutron diffraction analysis of residual stresses near unannealed welds in anhydrous ammonia nurse tanks.

    PubMed

    Becker, A T; Chumbley, L S; Goettee, D; Russell, A M

    2014-01-01

    Neutron diffraction analysis was employed to measure residual stresses near welds in used anhydrous ammonia nurse tanks. Tensile residual stresses contribute to stress corrosion cracking of nurse tanks, which can cause tanks to release toxic ammonia vapor. The analysis showed that tensile residual stresses were present in the tanks measured, and the magnitudes of these stresses approached the yield strength of the steel. Implications for agricultural safety and health are discussed.

  8. Residual stresses and plastic deformation in GTA-welded steel

    SciTech Connect

    Brand, P.C. ); Keijser, T.H. de; Ouden, G. den )

    1993-03-01

    Residual stresses and plastic deformation in single pass GTA welded low-carbon steel were studied by means of x-ray diffraction in combination with optical microscopy and hardness measurements. The residual stresses and the amount of plastic deformation (microstrain) were obtained from x-ray diffraction line positions and line broading. Since the plates were polished before welding, it was possible to observe in the optical microscope two types of Lueders bands. During heating curved Lueders bands and during cooling straight Lueders bands perpendicular to the weld are formed. The curved Lueders bands extend over a larger distance from the weld than the straight Lueders bands. The amount of plastic deformation as obtained from the x-ray diffraction analysis is in agreement with these observations. An explanation is offered for the stresses measured in combination with plastic deformations observed. It is concluded that in the present experiments plastic deformation is the main cause of the residual stresses.

  9. Modeling Residual Stresses in Ceramic Plates

    SciTech Connect

    Cantavella, V.; Moreno, A.; Mezquita, A.; Reig, Y.

    2008-02-15

    The generation of residual stresses during cooling of layered ceramic plates has been modeled. Each plate comprises a body and two thin layers (engobe and glaze). The model takes into account two types of stresses: thermal stresses, resulting from temperature gradients inside the plate during cooling, and the stresses produced by the mismatch of the coefficient of thermal expansion (CTE) of the layers. The body has been simulated using a linear viscoelastic constitutive equation. The engobe and the glaze layer have been considered as elastic solids below a certain temperature (setting temperature: T{sub a}). Above T{sub a} these two layers have no mechanical influence on the body.

  10. Modeling Residual Stresses in Ceramic Plates

    NASA Astrophysics Data System (ADS)

    Cantavella, V.; Moreno, A.; Mezquita, A.; Reig, Y.

    2008-02-01

    The generation of residual stresses during cooling of layered ceramic plates has been modeled. Each plate comprises a body and two thin layers (engobe and glaze). The model takes into account two types of stresses: thermal stresses, resulting from temperature gradients inside the plate during cooling, and the stresses produced by the mismatch of the coefficient of thermal expansion (CTE) of the layers. The body has been simulated using a linear viscoelastic constitutive equation. The engobe and the glaze layer have been considered as elastic solids below a certain temperature (setting temperature: Ta). Above Ta these two layers have no mechanical influence on the body.

  11. Residual stresses in bilayer dental ceramics.

    PubMed

    Taskonak, Burak; Mecholsky, John J; Anusavice, Kenneth J

    2005-06-01

    It is clinically observed that lithia-disilicate-based all-ceramic fixed partial dentures (FPD) can fail because of the fragmentation of the veneering material. The hypothesis of this study is that the global residual stresses within the surface of those veneered FPDs may be responsible for partial fragmentation of the veneering ceramic. Bilayer and monolithic ceramic composites were prepared using a lithia disilicate based (Li2OSiO2) glass-ceramic core and a glass veneer. A four-step fracture mechanics approach was used to analyze residual stress in bilayered all-ceramic FPDs. We found a statistically significant increase in the mean flexural strengths of bilayer specimens compared with monolithic glass specimens (p < or = 0.05). There was a statistically significant difference between the mean longitudinal and transverse indentation-induced crack sizes in bilayer specimens (p < or = 0.05), which indicates the existence of residual stress. Global residual stresses in the veneer layer, calculated using a fracture mechanics equation, were determined to be responsible for the increased strength and observed chipping, i.e., spallation in bilayer ceramic composites.

  12. Modeling of residual stresses by HY-100 weldments

    SciTech Connect

    Zacharia, T.; Taljat, B.; Radhakrishnan, B.

    1997-02-01

    Residual stress distribution in a HY-100 steel disk, induced by GTA spot welding, was analyzed by finite element (FE) formulations and measured by neutron diffraction (ND). Computations used temperature- dependent thermophysical and mechanical properties. FE model predictions are in good agreement with ND data in far heat affected zone (HAZ) and in base metal. Predicted residual stresses in fusion zone and near HAZ were higher than those measured by ND. This discrepancy was attributed to microstructural changes and associated material properties in the HAZ and fusion zone due to phase transformations during the weld thermal cycle.

  13. Determination of Residual Stress in Composite Materials Using Ultrasonic Waves

    NASA Technical Reports Server (NTRS)

    Rokhlin, S. I.

    1997-01-01

    The performance of high temperature composites can be significantly affected by the presence of residual stresses. These stresses arise during cooling processes from fabrication to room temperature due to mismatch of thermal expansion coefficients between matrix and fiber materials. This effect is especially pronounced in metal matrix and intermetallic composites. It can lead to plastic deformations, matrix cracking and fiber/matrix interface debonding. In this work the feasibility of ultrasonic techniques for residual stress assessment in composites is addressed. A novel technique for absolute stress determination in orthotropic materials from angular dependencies of ultrasonic velocities is described. The technique is applicable for determination of both applied and residual stresses and does not require calibration measurements on a reference sample. The important advantage of this method is that stress is determined simultaneously with stress-dependent elastic constants and is thus decoupled from the material texture. It is demonstrated that when the principal plane stress directions coincide with acoustical axes, the angular velocity data in the plane perpendicular to the stress plane may be used to determine both stress components. When the stress is off the acoustical axes, the shear and the difference of the normal stress components may be determined from the angular dependence of group velocities in the plane of stresses. Synthetic sets of experimental data corresponding to materials with different anisotropy and stress levels are used to check the applicability of the technique. The method is also verified experimentally. A high precision ultrasonic wave transmission technique is developed to measure angular dependence of ultrasonic velocities. Examples of stress determination from experimental velocity data are given. A method is presented for determination of velocities of ultrasonic waves propagating through the composite material with residual

  14. Computational modelling of bone cement polymerization: temperature and residual stresses.

    PubMed

    Pérez, M A; Nuño, N; Madrala, A; García-Aznar, J M; Doblaré, M

    2009-09-01

    The two major concerns associated with the use of bone cement are the generation of residual stresses and possible thermal necrosis of surrounding bone. An accurate modelling of these two factors could be a helpful tool to improve cemented hip designs. Therefore, a computational methodology based on previous published works is presented in this paper combining a kinetic and an energy balance equation. New assumptions are that both the elasticity modulus and the thermal expansion coefficient depend on the bone cement polymerization fraction. This model allows to estimate the thermal distribution in the cement which is later used to predict the stress-locking effect, and to also estimate the cement residual stresses. In order to validate the model, computational results are compared with experiments performed on an idealized cemented femoral implant. It will be shown that the use of the standard finite element approach cannot predict the exact temporal evolution of the temperature nor the residual stresses, underestimating and overestimating their value, respectively. However, this standard approach can estimate the peak and long-term values of temperature and residual stresses within acceptable limits of measured values. Therefore, this approach is adequate to evaluate residual stresses for the mechanical design of cemented implants. In conclusion, new numerical techniques should be proposed in order to achieve accurate simulations of the problem involved in cemented hip replacements.

  15. Residual stress characterization with an ultrasonic/magnetic technique

    NASA Technical Reports Server (NTRS)

    Namkung, M.; Heyman, J. S.

    1984-01-01

    A potentially useful new technique for residual stress characterization in ferromagnetic material is described. The unique feature of this technique is the measurement of small changes in ultrasonic wave velocity by the application of external dc magnetic field in the material under various stress conditions. It was found, in steel, that the fractional change in the natural velocity Delta W/W of waves propagating along the external field direction is affected by the uniaxial stress applied in the same axis. External compression lowers the slope of the Delta W/W curve in the low field region, while external tension generally does the opposite. For most cases, the slope in this region falls below zero under external compression. The result of measurements in specimens with residual stress shows exactly the same tendency.

  16. Characterization of welding residual stresses with neutron diffraction

    SciTech Connect

    Wang, X.L.; Spooner, S.; Hubbard, C.R.; Taljat, B.; Feng, Z.

    1998-03-01

    Welding residual stresses are a key concern in the fabrication and use of structural components containing welds. Residual stresses in welds are caused by non-uniform expansion and shrinkage of differently heated zones during the thermal transient of a weld pass. In some alloys, solid state phase transformations occurring during the welding transient contribute additional residual stresses. Manufacturing problems arising from welding residual stresses include cracking and dimensional distortion. During use, tensile stresses in the welded zone limit the fatigue resistance of the component under cyclic loading. In an aggressive environment, tensile welding residual stresses also create a necessary condition for stress-corrosion cracking to take place.

  17. Residual Stresses in 21-6-9 Stainless Steel Warm Forgings

    SciTech Connect

    Everhart, Wesley A.; Lee, Jordan D.; Broecker, Daniel J.; Bartow, John P.; McQueen, Jamie M.; Switzner, Nathan T.; Neidt, Tod M.; Sisneros, Thomas A.; Brown, Donald W.

    2012-11-14

    Forging residual stresses are detrimental to the production and performance of derived machined parts due to machining distortions, corrosion drivers and fatigue crack drivers. Residual strains in a 21-6-9 stainless steel warm High Energy Rate Forging (HERF) were measured via neutron diffraction. The finite element analysis (FEA) method was used to predict the residual stresses that occur during forging and water quenching. The experimentally measured residual strains were used to calibrate simulations of the three-dimensional residual stress state of the forging. ABAQUS simulation tools predicted residual strains that tend to match with experimental results when varying yield strength is considered.

  18. Residual stresses in injection molded shape memory polymer parts

    NASA Astrophysics Data System (ADS)

    Katmer, Sukran; Esen, Huseyin; Karatas, Cetin

    2016-03-01

    Shape memory polymers (SMPs) are materials which have shape memory effect (SME). SME is a property which has the ability to change shape when induced by a stimulator such as temperature, moisture, pH, electric current, magnetic field, light, etc. A process, known as programming, is applied to SMP parts in order to alter them from their permanent shape to their temporary shape. In this study we investigated effects of injection molding and programming processes on residual stresses in molded thermoplastic polyurethane shape memory polymer, experimentally. The residual stresses were measured by layer removal method. The study shows that injection molding and programming process conditions have significantly influence on residual stresses in molded shape memory polyurethane parts.

  19. Patterns of residual stresses due to welding

    NASA Technical Reports Server (NTRS)

    Botros, B. M.

    1983-01-01

    Residual stresses caused by welding result from the nonuniform rate of cooling and the restrained thermal contraction or non-uniform plastic deformation. From the zone of extremely high temperature at the weld, heat flows into both the adjoining cool body and the surrounding atmosphere. The weld metal solidifies under very rapid cooling. The plasticity of the hot metal allows adjustment initially, but as the structure cools the rigidity of the surrounding cold metal inhibits further contraction. The zone is compressed and the weld is put under tensile stresses of high magnitude. The danger of cracking in these structural elements is great. Change in specific volume is caused by the change in temperature.

  20. Residual Stress in Composites with the Thin-ring-slitting Approach

    PubMed Central

    Park, J.W.; Ferracane, J.L.

    2008-01-01

    During polymerization, dental composites develop residual stresses that may compromise the marginal integrity and properties of the restorative. The objective of this study was to use the thin-walled ring-slitting method to measure and compare residual stresses. The hypotheses to be tested were that composites would generate different levels of residual stress based on their specific formulations and slitting times. Rings made from composites (Z100, Herculite, and Heliomolar) were cut at different times (10 min, 1 and 24 hrs) after being light-cured, and stress was measured. Residual stress was higher at the earlier cutting times, except for Heliomolar (α < 0.05). For the 10-minute and one-hour cutting groups, stress followed this order: Z100 > Herculite > Heliomolar. Early slitting was better to capture residual stress, and the thin-walled rings showed higher values than thick-walled rings and were better able to discriminate residual stress in composites. PMID:16998138

  1. Analytical solutions for determining residual stresses in two-dimensional domains using the contour method

    PubMed Central

    Kartal, Mehmet E.

    2013-01-01

    The contour method is one of the most prevalent destructive techniques for residual stress measurement. Up to now, the method has involved the use of the finite-element (FE) method to determine the residual stresses from the experimental measurements. This paper presents analytical solutions, obtained for a semi-infinite strip and a finite rectangle, which can be used to calculate the residual stresses directly from the measured data; thereby, eliminating the need for an FE approach. The technique is then used to determine the residual stresses in a variable-polarity plasma-arc welded plate and the results show good agreement with independent neutron diffraction measurements. PMID:24204187

  2. Experimental investigation of residual stress distribution during turning of weak stiffness revolving parts

    NASA Astrophysics Data System (ADS)

    Jiao, Sicheng; Zhang, Chengyan; Liu, Guancheng; Lu, Jiping; Tang, Shuiyuan

    2017-08-01

    A series of turning experiments have been carried out to study the effect of different cutting speed, feed rate and pre-tightening torque on residual stress distribution during turning of weak stiffness revolving parts. Surface residual stress and the peak residual compressive stress are selected from the typical residual stress distribution profile. The residual stress by turning was measured by X-ray diffraction method. In order to get the distribution of residual stress along depth direction, the specimens need to be etched layer by layer. From this investigation, it can be concluded that it is practicable to control the distribution of residual stress by changing the pre-tightening torque and cutting parameters during turning of weak stiffness revolving parts.

  3. Residual stresses in continuous graphite fiber Al metal matrix composites

    NASA Technical Reports Server (NTRS)

    Park, Hun Sub; Zong, Gui Sheng; Marcus, Harris L.

    1988-01-01

    The residual stresses in graphite fiber reinforced aluminum (Gr/Al) composites with various thermal histories are measured using X-ray diffraction (XRD) methods. The XRD stress analysis is based on the determination of lattice strains by precise measurements of the interplanar spacings in different directions of the sample. The sample is a plate consisting of two-ply P 100 Gr/Al 6061 precursor wires and Al 6061 overlayers. Prior to XRD measurement, the 6061 overlayers are electrochemically removed. In order to calibrate the relationship between stress magnitude and lattice spacing shift, samples of Al 6061 are loaded at varying stress levels in a three-point bend fixture, while the stresses are simultaneously determined by XRD and surface-attached strain gages. The stresses determined by XRD closely match those determined by the strain gages. Using these calibrations, the longitudinal residual stresses of P 100 Gr/Al 6061 composites are measured for various heat treatments, and the results are presented.

  4. Residual stresses in continuous graphite fiber Al metal matrix composites

    NASA Technical Reports Server (NTRS)

    Park, Hun Sub; Zong, Gui Sheng; Marcus, Harris L.

    1988-01-01

    The residual stresses in graphite fiber reinforced aluminum (Gr/Al) composites with various thermal histories are measured using X-ray diffraction (XRD) methods. The XRD stress analysis is based on the determination of lattice strains by precise measurements of the interplanar spacings in different directions of the sample. The sample is a plate consisting of two-ply P 100 Gr/Al 6061 precursor wires and Al 6061 overlayers. Prior to XRD measurement, the 6061 overlayers are electrochemically removed. In order to calibrate the relationship between stress magnitude and lattice spacing shift, samples of Al 6061 are loaded at varying stress levels in a three-point bend fixture, while the stresses are simultaneously determined by XRD and surface-attached strain gages. The stresses determined by XRD closely match those determined by the strain gages. Using these calibrations, the longitudinal residual stresses of P 100 Gr/Al 6061 composites are measured for various heat treatments, and the results are presented.

  5. Residual stresses in sputter-deposited copper/330 stainless steel multilayers

    SciTech Connect

    Zhang, X.; Misra, A.

    2004-12-15

    The evolution of residual stresses as a function of bilayer period from 10 nm to 1 {mu}m in sputter-deposited Cu/330 stainless-steel (SS) multilayered films is evaluated by the substrate curvature technique. The multilayer stress evolution is compared with residual stresses in single layer Cu films and single layer 330 SS films, also measured by substrate curvature technique, with respective film thicknesses varying from 5 to 500 nm. Both single layer and multilayer films exhibit high tensile residual stresses that increase with decreasing layer thickness, but are found to be lower than the respective yield strengths. The intrinsic tensile residual stress evolution with film thickness is explained using the island coalescence model. The difference between the multilayer residual stress and the average residual stresses in single-layered Cu and 330 SS films is interpreted in terms of interface stress.

  6. Modeling Residual Stress Development in Thermal Spray Coatings: Current Status and Way Forward

    NASA Astrophysics Data System (ADS)

    Abubakar, Abba A.; Arif, Abul Fazal M.; Al-Athel, Khaled S.; Akhtar, S. Sohail; Mostaghimi, Javad

    2017-07-01

    An overview of analytical and numerical methods for prediction of residual stresses in thermal spray coatings is presented. The various sources and mechanisms underlying residual stress development in thermal spray coatings are discussed, then the various difficulties associated with experimental residual stress measurement in thermal spray coatings are highlighted. The various analytical and numerical models used for prediction of residual stresses in thermal spray coatings are thoroughly discussed. While analytical models for prediction of postdeposition thermal mismatch stresses are fully developed, analytical quenching and peening stress models still require extensive development. Various schemes for prediction of residual stresses using the finite element method are identified. The results of the various numerical and analytical models are critically analyzed, and their accuracy and validity, when compared with experiments, are discussed. Issues regarding the accuracy and applicability of the models for predicting residual stresses in thermal spray coatings are highlighted, and several suggestions for future development of the models are given.

  7. Modeling Residual Stress Development in Thermal Spray Coatings: Current Status and Way Forward

    NASA Astrophysics Data System (ADS)

    Abubakar, Abba A.; Arif, Abul Fazal M.; Al-Athel, Khaled S.; Akhtar, S. Sohail; Mostaghimi, Javad

    2017-08-01

    An overview of analytical and numerical methods for prediction of residual stresses in thermal spray coatings is presented. The various sources and mechanisms underlying residual stress development in thermal spray coatings are discussed, then the various difficulties associated with experimental residual stress measurement in thermal spray coatings are highlighted. The various analytical and numerical models used for prediction of residual stresses in thermal spray coatings are thoroughly discussed. While analytical models for prediction of postdeposition thermal mismatch stresses are fully developed, analytical quenching and peening stress models still require extensive development. Various schemes for prediction of residual stresses using the finite element method are identified. The results of the various numerical and analytical models are critically analyzed, and their accuracy and validity, when compared with experiments, are discussed. Issues regarding the accuracy and applicability of the models for predicting residual stresses in thermal spray coatings are highlighted, and several suggestions for future development of the models are given.

  8. Effects of residual stresses on fracture of welded pipes

    SciTech Connect

    Hou, Y.C.; Kim, M,; Pan, J.; Brust, F.W.

    1996-12-01

    Thermal residual stresses induced by multi-pass butt welding processes of stainless steel pipes are obtained by a thermoelastic-plastic finite element analysis with the assumption of axisymmetric conditions. After the welding processes, circumferential part-through cracks are introduced at the locations having the highest axial residual stress. Crack-tip parameters are sought for characterizing the crack-tip stress and deformation field under subsequent applied axial stresses. The computational results indicate that without residual stress mitigation processes, the residual stresses are quite large and the J integrals for several arbitrary paths are path dependent under the range of axial stresses. Therefore, J cannot be used as a characterizing parameter under the applied stresses. The results also show that, as the axial stress becomes large, the J integrals for different paths follow the same trend as those without residual stresses. This indicates that the residual stress effects become less significant when the deformation due to the applied axial stress becomes dominant. Finally, a computationally convenient parameter, the crack tip opening angle (CTOA), which can take into account the effects of residual stresses near the tip, is adopted for characterizing the crack tip deformation. The CTOA results suggest that with residual stresses the propensity for subcritical crack growth via a stress corrosion cracking or fatigue crack growth mechanism in welds may be higher than that without residual stresses.

  9. Minimization of Residual Stress in an Al-Cu Alloy Forged Plate by Different Heat Treatments

    NASA Astrophysics Data System (ADS)

    Dong, Ya-Bo; Shao, Wen-Zhu; Jiang, Jian-Tang; Zhang, Bao-You; Zhen, Liang

    2015-06-01

    In order to improve the balance of mechanical properties and residual stress, various quenching and aging treatments were applied to Al-Cu alloy forged plate. Residual stresses determined by the x-ray diffraction method and slitting method were compared. The surface residual stress measured by x-ray diffraction method was consistent with that measured by slitting method. The residual stress distribution of samples quenched in water with different temperatures (20, 60, 80, and 100 °C) was measured, and the results showed that the boiling water quenching results in a 91.4% reduction in residual stress magnitudes compared with cold water quenching (20 °C), but the tensile properties of samples quenched in boiling water were unacceptably low. Quenching in 80 °C water results in 75% reduction of residual stress, and the reduction of yield strength is 12.7%. The residual stress and yield strength level are considerable for the dimensional stability of aluminum alloy. Quenching samples into 30% polyalkylene glycol quenchants produced 52.2% reduction in the maximum compressive residual stress, and the reduction in yield strength is 19.7%. Moreover, the effects of uphill quenching and thermal-cold cycling on the residual stress were also investigated. Uphill quenching and thermal-cold cycling produced approximately 25-40% reduction in residual stress, while the effect on tensile properties is quite slight.

  10. Influence of residual stresses on ceramic-metal interfacial toughness

    NASA Astrophysics Data System (ADS)

    Thurston, Mark Edward

    The critical property determining the extent to which ductile metal reinforcing particles can toughen a brittle ceramic matrix is the toughness of the ceramic-metal interface between particle and matrix. Unfortunately, due to the lack of understanding of the mechanics of bimaterial interfaces in the presence of residual stresses, experimental data on the fracture toughness of ceramic-metal interfaces is scarce. Consequently, the purpose of the present work is to account for the influence of residual stresses on the measured fracture toughness of a representative nickel/alumina system and, in conjunction with a maximum hoop stress criterion, to explain the observed increase in toughness with increasing mixity of loading. A finite element model incorporating the rate-dependent inelastic behavior of nickel at high temperatures was implemented in order to provide a realistic estimate of the residual stresses that develop during the bonding process. The calculated Mises equivalent stresses in the nickel averaged between 110 and 115 MPa, well above the room temperature yield strength of 82 MPa. For the sandwich specimens adopted in the current study, a simple argument yields a critical foil thickness below which residual stress effects are expected to be minimal. The influence of differing foil thicknesses below this threshold is shown to be insignificant. For sandwich specimens a general result is demonstrated: compared to the same loading applied without residual stresses present, the effect of residual stresses is to decrease the magnitude of the phase angle that will develop along the interface. Microprobe measurements verified that by controlling the bonding atmosphere the formation of a reaction product at the interface was prevented, and that the fracture mechanism was pure cleavage of the interface. The measured interfacial toughness values increased from 11 J/sq m at psi-caret approximately equals 0 deg to 22 J/sq m at psi-caret approximately equals +/-23 deg

  11. Determination of Bulk Residual Stresses in Electron Beam Additive-Manufactured Aluminum

    NASA Astrophysics Data System (ADS)

    Brice, Craig A.; Hofmeister, William H.

    2013-11-01

    Additive-manufactured aluminum alloy deposits were analyzed using neutron diffraction to characterize the effect of intermediate stress relief anneal heat treatment on bulk residual stresses in the final part. Based on measured interplanar spacing, stresses were calculated at various locations along a single bead, stacked wall deposit. A comparison between an uninterrupted deposited wall and an interrupted, stress-relieved, and annealed deposited wall showed a measureable reduction in residual stress magnitude at the interface with a corresponding shift in stress character into the deposit. This shift changes the interface stresses from purely compressive to partially tensile. The residual stress profile varied along the length of the deposit, and the heat-treatment procedure reduced the overall magnitude of the stress at the interface by 10 through 25 MPa. These results are interpreted in terms of thermal gradients inherent to the process and compared with prior residual stress-characterization studies in additive-manufactured metallic structures.

  12. Amplified effect of mild plastic anisotropy on residual stress and strain anisotropy

    DOE PAGES

    Prime, Michael B.

    2017-07-01

    Axisymmetric indentation of a geometrically axisymmetric disk produced residual stresses by non-uniform plastic deformation. The 2024 aluminum plate used to make the disk exhibited mild plastic anisotropy with about 10% lower strength in the transverse direction compared to the rolling and through-thickness directions. Residual stresses and strains in the disk were measured with neutron diffraction, slitting, the contour method, x-ray diffraction and hole drilling. Surprisingly, the residual-stress anisotropy measured in the disk was about 40%, the residual-strain anisotropy was an impressive 100%, and the residual stresses were higher in the weaker direction. The high residual stress anisotropy relative to themore » mild plastic anisotropy and the direction of the highest stress are explained by considering the mechanics of indentation: constraint on deformation provided by the material surrounding the indentation and preferential deformation in the most compliant direction for incremental deformation. By contrast, the much larger anisotropy in residual strain compared to that in residual stress is independent of the fabrication process and is instead explained by considering Hookean elasticity. For Poisson's ratio of 1/3, the relationship simplifies to the residual strain anisotropy equaling the square of the residual stress anisotropy, which matches the observed results (2 ≈ 1.4^2). Furthermore, a lesson from this study is that to accurately predict residual stresses and strains, one must be wary of seemingly reasonable simplifying assumptions such as neglecting mild plastic anisotropy.« less

  13. Ultrasonic measurement of axial stress

    NASA Technical Reports Server (NTRS)

    Heyman, J. S.; Chern, E. J.

    1982-01-01

    The theory of acoustic propagation in strained media is examined, with particular emphasis on rod (bolt) geometries. The continuous wave (CW) approach is the basis of the study, and the theory is developed from a frequency domain analysis standpoint in order to obtain an applied stress/normalized frequency shift relationship. CW measurements may be influenced by such factors as propagation effects, mode conversion, frequency, material properties, and geometry. After the first loading cycle, axial stress measurements for a preloading with an initial frequency of 4.995 36 MHz dropped to 4.989 19 MHz, indicating a 6.17 kHz change. CW and pseudo-CW ultrasonic techniques are found to be reliable for axial stress measurements, and acoustic attenuation measurements correlated to residual stress fields may possibly involve transducer phase cancellation. It is thus concluded that signal drop is an artifact of the transducer directivity, rather than an actual acoustic power decrease.

  14. Residual stress and dislocations density in silicon ribbons grown via optical zone melting

    NASA Astrophysics Data System (ADS)

    Augusto, A.; Pera, D.; Choi, H. J.; Bellanger, P.; Brito, M. C.; Maia Alves, J.; Vallêra, A. M.; Buonassisi, T.; Serra, J. M.

    2013-02-01

    We investigate the relationships between growth rate, time-temperature profile, residual stress, dislocation density, and electrical performance of silicon ribbons grown via optical zone melting. The time-temperature profiles of ribbons grown at different velocities were investigated using direct measurements and computational fluid dynamics (CFD) modeling. Residual stresses up to 20 MPa were measured using infrared birefringence imaging. The effect of crystallization speed on dislocation density and residual stress is discussed from the context of thermal stresses during growth. More broadly, we demonstrate the usefulness of combining spatially resolved stress and microstructure measurements with CFD simulations toward optimizing kerfless silicon wafer quality.

  15. Residual stress depth profiles of ausrolled 9310 gear steel

    SciTech Connect

    Paliani, C.M.; Queeney, R.A.; Kozaczek, K.J.

    1995-12-31

    Residual Stress analysis utilizing x-ray diffraction in conjunction with material removal by chemical polishing provides a very effective method of analyzing the near surface residual stress profile of steels. In this experiment, residual stress profiling has been used to analyze the effects of surface ausrolling during the marquenching of a 9310 gear steel which has been carburized to 1% carbon. The ausrolling process is an advanced thermomechanical processing technique used to ausform only the critical surface layer of gears and produce a hard, tough, fine-grained martensitic product. This study compares the residual stress profile of a marquenched specimen with a moderately deformed ausrolled specimen and with a heavily deformed ausrolled specimen, in order to correlate the effects of residual stress with the improved fatigue properties of the gear steel. While no significant variation was observed between the residual stress profile of the marquenched specimens (no deformation) and the line contact ausrolled specimens (moderate deformation), significant increases in the amount of compressive residual stress was noted in the residual stress profile of the point contact ausrolled (heavily deformed) samples. The maximum increase in compressive residual stress due to point contact ausrolling was approximately 500 MPa, when compared to the marquenched sample. This increased residual compressive stress will lower the effective shear stresses during rolling contact fatigue and would therefore explain some of the increase the rolling contact fatigue endurance of the point contact ausrolled specimens.

  16. Thermoelastic Stress Analysis: An NDE Tool for the Residual Stress Assessment of Metallic Alloys

    NASA Technical Reports Server (NTRS)

    Gyekenyesi, Andrew L.; Baaklini, George Y.

    2000-01-01

    During manufacturing, certain propulsion components that will be used in a cyclic fatigue environment are fabricated to contain compressive residual stresses on their surfaces because these stresses inhibit the nucleation of cracks. Overloads and elevated temperature excursions cause the induced residual stresses to dissipate while the component is still in service, lowering its resistance to crack initiation. Research at the NASA Glenn Research Center at Lewis Field has focused on employing the Thermoelastic Stress Analysis technique (TSA, also recognized as SPATE: Stress Pattern Analysis by Thermal Emission) as a tool for monitoring the residual stress state of propulsion components. TSA is based on the fact that materials experience small temperature changes when they are compressed or expanded. When a structure is cyclically loaded (i.e., cyclically compressed and expanded), the resulting surface-temperature profile correlates to the stress state of the structure s surface. The surface-temperature variations resulting from a cyclic load are measured with an infrared camera. Traditionally, the temperature amplitude of a TSA signal has been theoretically defined to be linearly dependent on the cyclic stress amplitude. As a result, the temperature amplitude resulting from an applied cyclic stress was assumed to be independent of the cyclic mean stress.

  17. Evolution of Residual Stresses with Fatigue Crack Growth in a Variable Polarity Plasma Arc Welded Aluminum Alloy Compact Tension Specimen

    NASA Astrophysics Data System (ADS)

    Liljedahl, C. D. M.; Zanellato, O.; Edwards, L.; Fitzpatrick, M. E.

    2008-10-01

    The evolution of the residual stresses during fatigue crack growth in a welded compact tension C(T) specimen was measured using neutron diffraction. The measurements were performed by growing a fatigue crack in a sample in situ on a neutron diffractometer. The stresses were found to be unaffected by crack growth through the compressive part of the initial residual stress field. The residual stresses at the crack tip increased when the crack entered the tensile residual stress field to maintain residual stress equilibrium. Finite element (FE) modeling of the evolution of the residual stresses showed good correlation with the experimental results. The residual stress evolution was found to be governed by redistribution of the initial stress field and only slightly affected by fatigue-induced effects at the measured spatial resolution (2 mm × 2 mm × 7 mm).

  18. RGB photoelasticity applied to the analysis of membrane residual stress in glass

    NASA Astrophysics Data System (ADS)

    Ajovalasit, A.; Petrucci, G.; Scafidi, M.

    2012-02-01

    The measurement of residual stresses is of great relevance in the glass industry. The analysis of residual stress in glass is usually made by photoelastic methods because glass is a photoelastic material. This paper considers the determination of membrane residual stresses in glass plates by automatic digital photoelasticity in white light (RGB photoelasticity). The proposed method is applied to the analysis of membrane residual stresses in some tempered glass. The proposed method can effectively replace manual methods based on the use of white light, which are currently provided by some technical standards.

  19. Internal surface residual stresses in girth butt-welded steel pipes

    SciTech Connect

    Mohr, W.C.

    1996-12-01

    Welding residual stresses are often needed as inputs in fitness for service determinations. This paper collects data on the welding residual stress at the internal surface of girth welds in steel pipes. Comparing the available measurements at the weld centerline, large variations can be noted in residual stress, both in the axial and hoop direction, even on pipes of similar thickness. The range can be somewhat reduced by including the effects of welding net heat input and material yield strength, but at best the range is {+-} 0.4 yield strength. Mechanisms of residual stress formation and estimation techniques are discussed.

  20. Residual stress delaying phase transformation in Y-TZP bio-restorations

    NASA Astrophysics Data System (ADS)

    Allahkarami, Masoud; Hanan, Jay C.

    2012-01-01

    Engineering favorable residual stress for the complex geometry of bi-layer porcelain-zirconia crowns potentially prevents crack initiation and improves the mechanical performance and lifetime of the dental restoration. In addition to external load, the stress field depends on initial residual stress before loading. Residual stress is the result of factors such as the thermal expansion mismatch of layers and compliance anisotropy of zirconia grains in the process of sintering and cooling. Stress induced phase transformation in zirconia extensively relaxes the residual stress and changes the stress state. The objective of this study is to investigate the coupling between tetragonal to monoclinic phase transformations and residual stress. Residual stress, on the surface of the sectioned single load to failure crown, at 23 points starting from the pure tetragonal and ending at a fully monoclinic region were measured using the micro X-ray diffraction sin2 ψ method. An important observation is the significant range in measured residual stress from a compressive stress of -400 MPa up to tensile stress of 400 MPa and up to 100% tetragonal to monoclinic phase transformation.

  1. The influence of quench sensitivity on residual stresses in the aluminium alloys 7010 and 7075

    SciTech Connect

    Robinson, J.S.; Tanner, D.A.; Truman, C.E.; Paradowska, A.M.; Wimpory, R.C.

    2012-03-15

    The most critical stage in the heat treatment of high strength aluminium alloys is the rapid cooling necessary to form a supersaturated solid solution. A disadvantage of quenching is that the thermal gradients can be sufficient to cause inhomogeneous plastic deformation which in turn leads to the development of large residual stresses. Two 215 mm thick rectilinear forgings have been made from 7000 series alloys with widely different quench sensitivity to determine if solute loss in the form of precipitation during quenching can significantly affect residual stress magnitudes. The forgings were heat treated and immersion quenched using cold water to produce large magnitude residual stresses. The through thickness residual stresses were measured by neutron diffraction and incremental deep hole drilling. The distribution of residual stresses was found to be similar for both alloys varying from highly triaxial and tensile in the interior, to a state of biaxial compression in the surface. The 7010 forging exhibited larger tensile stresses in the interior. The microstructural variation from surface to centre for both forgings was determined using optical and transmission electron microscopy. These observations were used to confirm the origin of the hardness variation measured through the forging thickness. When the microstructural changes were accounted for in the through thickness lattice parameter, the residual stresses in the two forgings were found to be very similar. Solute loss in the 7075 forging appeared to have no significant effect on the residual stress magnitudes when compared to 7010. - Highlights: Black-Right-Pointing-Pointer Through thickness residual stress measurements made on large Al alloy forgings. Black-Right-Pointing-Pointer Residual stress characterised using neutron diffraction and deep hole drilling. Black-Right-Pointing-Pointer Biaxial compressive surface and triaxial subsurface residual stresses. Black-Right-Pointing-Pointer Quench sensitivity

  2. An Investigation of Residual Stresses in Machined Silicon Nitride

    DTIC Science & Technology

    1992-07-01

    passing the particles through a 325-mesh screen. Methodologies for the experimental determination of residual stress include Barkhausen noise analysis...AD-A254 635 ~jjMTL TR 92-46 - 154 kDl AN INVESTIGATION OF RESIDUAL STRESSES IN MACHINED SILICON NITRIDE DANIEL J. SNOHA U.S. ARMY MATERIALS...NUMBER MTL TR 92-46 4. TITLE (and Subtitle) 5. TYPE OF REPORT & PERIOD COVERED AN INVESTIGATION OF RESIDUAL STRESSES IN Final Report MACHINED SILICON

  3. A residual stress study in similar and dissimilar welds

    DOE PAGES

    Eisazadeh, Hamid; Goldak, John A.; Aidun, Daryush K.; ...

    2016-04-01

    Residual strain distributions in similar and dissimilar welds were measured using neutron diffraction (ND) method. Then, using three strain components, three-dimensional stress states were calculated. The results were used to determine the effect of the martensitic phase transformation and material properties on residual stress (RS) distribution. It was observed that smaller longitudinal RS was induced in the low carbon steel side of dissimilar weld when compared to its similar weld. Also, it was found that the transverse RS near and within the weld zone (WZ) in dissimilar weld exhibited a distinctive trend, with tensile mode reaching the yield strength ofmore » the base metal (BM). In order to characterize the WZ in dissimilar weld, we deployed optical microscopy, hardness, and energy dispersive X-ray spectroscopy (EDAX). This study not only provides further insight into the RS state in similar and dissimilar welds; it also delivers important consequences of phase transformation in the latter case.« less

  4. A residual stress study in similar and dissimilar welds

    SciTech Connect

    Eisazadeh, Hamid; Goldak, John A.; Aidun, Daryush K.; Coules, Harry E.; Bunn, Jeffrey R; Achuthan, A.

    2016-04-01

    Residual strain distributions in similar and dissimilar welds were measured using neutron diffraction (ND) method. Then, using three strain components, three-dimensional stress states were calculated. The results were used to determine the effect of the martensitic phase transformation and material properties on residual stress (RS) distribution. It was observed that smaller longitudinal RS was induced in the low carbon steel side of dissimilar weld when compared to its similar weld. Also, it was found that the transverse RS near and within the weld zone (WZ) in dissimilar weld exhibited a distinctive trend, with tensile mode reaching the yield strength of the base metal (BM). In order to characterize the WZ in dissimilar weld, we deployed optical microscopy, hardness, and energy dispersive X-ray spectroscopy (EDAX). This study not only provides further insight into the RS state in similar and dissimilar welds; it also delivers important consequences of phase transformation in the latter case.

  5. Surface wave propagation in thin silver films under residual stress

    NASA Astrophysics Data System (ADS)

    Njeh, Anuar; Wieder, Thomas; Schneider, D.; Fuess, Hartmut; Ben Ghozlen, M. H.

    Investigations using surface acoustic waves provide information on the elastic properties of thin films. Residual stresses change the phase velocity of the surface waves. We have calculated phase velocity and dispersion of surface waves in thin silver films with a strong [111]-fibre texture. A non-linear description of surface waves propagating along the [110]-direction of the substrate has been developed on the basis of an acoustoelastic theory, taking into account residual stresses. The relative change delta_v/v of the velocity v was found to be lin-ear for large excitation frequencies. The dispersion curves were measured using a photoa-coustic method. For sputtered polycrystalline thin silver films we found good agreement be-tween the experimental and calculated dispersion curves for frequencies up to 225 MHz.

  6. Method of characterizing residual stress in ferromagnetic materials using a pulse histogram of acoustic emission signals

    NASA Technical Reports Server (NTRS)

    Namkung, Min (Inventor); Yost, William T. (Inventor); Kushnick, Peter W. (Inventor); Grainger, John L. (Inventor)

    1992-01-01

    The invention is a method and apparatus for characterizing residual uniaxial stress in a ferromagnetic test member by distinguishing between residual stresses resulting from positive (tension) forces and negative (compression) forces by using the distinct and known magnetoacoustic (MAC) and a magnetoacoustic emission (MAE) measurement circuit means. A switch permits the selective operation of the respective circuit means.

  7. Evaluating the influence of residual stresses on the magnetic properties of electrical steel

    SciTech Connect

    Korzunin, G.S.; Chistyakov, V.K.

    1995-04-01

    The method described for evaluating the influence of residual stresses on the magnetic properties of coiled cold-rolled electrical steel consists in measuring the ratio of the magnetic characteristics that are and are not sensitive to the effect of residual stresses. The evaluation is made from the value of the ratio, using the correlations between its value and the magnetic characteristics studied.

  8. Validation Specimen for Contour Method Extension to Multiple Residual Stress Components

    SciTech Connect

    Pagliaro, Pierluigi; Prime, Michael B; Zuccarello, B; Clausen, Bjorn; Watkins, Thomas R

    2007-01-01

    A new theoretical development of the contour method, that allow the user to measure the three normal residual stress components on cross sections of a generic mechanical part, is presented. To validate such a theoretical development, a residual stress test specimen was properly designed, fabricated and then tested with different experimental techniques.

  9. The Effect of Creep on the Residual Stresses Generated During Silicon Sheet Growth

    NASA Technical Reports Server (NTRS)

    Hutchinson, J. W.; Lambropoulos, J. C.

    1984-01-01

    The modeling of stresses generated during the growth of thin silicon sheets at high speeds is an important part of the EFG technique since the experimental measurement of the stresses is difficult and prohibitive. The residual stresses which arise in such a growth process lead to serious problems which make thin Si ribbons unsuitable for fabrication. The constitutive behavior is unrealistic because at high temperature (close to the melting point) Si exhibits considerable creep which significantly relaxes the residual stresses. The effect of creep on the residual stresses generated during the growth of Si sheets at high speeds was addressed and the basic qualitative effect of creep are reported.

  10. Residual stresses in coronary artery stents.

    PubMed

    Möller, D; Reimers, W; Pyzalla, A; Fischer, A

    2001-01-01

    In western industrial countries, coronary heart disease is the most common cause of death. The reason is a coronary sclerosis, which by the generation of plaques narrows the inner lumen of an artery and, thus, deteriorates the blood supply. This leads to symptoms like burning pain or increased pressure in the chest, and finally to an under supply and damage of the heart muscle. In order to keep those portions of arteries that are covered by a plaque open, the stent technique was developed in the 1980s and is increasingly used since about 13 years. These stents are usually made of wires or of a slotted tube and are of two kinds: self-expanding and balloon expanding. Both types are implanted after being mounted on a catheter and expanded in the desired position. Self-expanding stents make use of the elastic deformation, while the other group of stents are expanded by a balloon, which brings about a plastic deformation of certain regions of the stent structure. Thus, after implantation, parts of these stents undergo two steps of distinct plastic deformation. First during compression, which is necessary for the mounting procedure on the catheter (crimping), and second during expansion for implantation. In this article, the residual stresses generated during crimping and expansion are presented and discussed. These stresses are stored in the structure of a portion of a stent after implantation and are superimposed on those stresses generated by the more than 700 million cyclic heart beats during the patient's life. This work is a part of several interdisciplinary research projects by the authors in order to gain reliable fail-safe criteria for the static and cyclic mechanical properties of coronary stents.

  11. Thermal Stability of Residual Stresses in Ti-6Al-4V components

    NASA Astrophysics Data System (ADS)

    Stanojevic, A.; Angerer, P.; Oberwinkler, B.

    2016-03-01

    The need for light weight design while maintaining a high safety is essential for many components, especially in the aircraft industry. Therefore, it's important to consider every aspect to reduce weight, improve fatigue life and maintain safety of crucial components. Residual stresses are a major factor which can positively influence components and fulfil all three requirements. However, due to the inconstancy of the behaviour of residual stresses during the life time of a component, residual stresses are often neglected. If the behaviour of residual stresses could be described reliably over the entire life time of a component, residual stresses could be taken into account and components could be optimized even further. Mechanical and thermal loads are the main reason for relaxation of residual stresses. This work covers the thermal stability of residual stresses in Ti-6Al-4V components. Therefore, exposure tests at raised temperatures were performed on specimens with different surface conditions. Residual stresses were measured by x-ray diffraction before and after testing. Creep tests were also carried out to describe the creep behaviour and thereby the ability for residual stress relaxation. A correlation between the creep rate and amount of relaxed stress was found. The creep behaviour of the material was described by using a combination of the Norton Power law and the Arrhenius equation. The Zener-Wert-Avrami model was used to describe the residual stress relaxation. With these models a satisfying correlation between measured and calculated data was found. Hence, the relaxation of residual stresses due to thermal load was described reliably.

  12. Effect of Thermal Annealing on Machining-Induced Residual Stresses in Inconel 718

    NASA Astrophysics Data System (ADS)

    Madariaga, A.; Aperribay, J.; Arrazola, P. J.; Esnaola, J. A.; Hormaetxe, E.; Garay, A.; Ostolaza, K.

    2017-08-01

    Nickel-based alloys are widely employed in the manufacturing of aero-engines. These alloys are difficult to machine, and tensile residual stresses are generated during machining. These tensile residual stresses can negatively affect the performance of aero-engine components. Nevertheless, residual stresses can vary due to thermal or mechanical loading. These variations must be considered to evaluate the real influence of residual stresses on component behavior. This paper studies the effect of thermal loads on machining-induced residual stresses in the alloy Inconel 718. A ring-shaped Inconel 718 part was face-turned, and specimens were extracted from it. Specimens were exposed at 550 and 650 °C for 10 min, 1 and 10 h. Residual stresses were measured, and microstructure was observed before and after thermal exposure. Residual stress variations found after thermal exposure were the consequence of two factors: relaxation of strain bands during the early stage of exposure and diffusion-controlled creep. In addition, a modified Zener-Wert-Avrami model is proposed to predict residual stress relaxation caused by the diffusion-controlled creep. Once having fitted the modified Zener-Wert-Avrami model, the study was extended for a wider range of temperatures (400-650 °C). This analysis showed that surface residual stresses do not relax significantly at temperatures below 500 °C.

  13. Magnetoacoustic stress measurements in steel

    NASA Technical Reports Server (NTRS)

    Namkung, M.; Utrata, D.; Allison, S. G.; Heyman, J. S.

    1985-01-01

    Uniaxial stress effects on the low-field magnetoacoustic interaction have been studied using bulk compressional waves and Rayleigh surface waves in numerous steel samples having various impurity concentrations (Namkung et al., 1984). The results invariably showed that the initial slope of acoustic natural velocity variations, with respect to net induced magnetization parallel to the stress axis, is positive under tension and negative under compression. The results of current measurements in railroad rail steel having about 0.68 wt percent carbon content are typical for medium range carbon steels. The low-field natural velocity slope in this particular type of steel, which is almost zero when unstressed, becomes steeper with increased magnitude of stress in both directions. Hence, the nondestructive determination of the sign of residual stress in railroad wheels and rails is possible using this technique. This paper discusses the basic physical mechanism underlying the experimental observations and presents the results obtained in railroad rail steel.

  14. Residual stress near cracks of K and fused silica under 1064 nm nanosecond laser irradiation

    NASA Astrophysics Data System (ADS)

    Zhang, Zhen; Liu, Hongjie; Huang, Jin; Zhou, Xiaoyan; Ren, Dahua; Cheng, Xinlu; Jiang, Xiaodong; Wu, Weidong; Zheng, Wanguo

    2012-11-01

    Measurements of birefringence induced in K9 and fused silica specimens by cracks produced by 1064 nm Nd∶YAG laser have been presented. The Birefringence data is converted into the units of stress, thus permitting the estimation of residual stress near crack. The intensity of residual stress in K9 glass is larger than that in fused silica under the same condition. The similarity of residual stress distribution along the y-axis reveals that the nature of shock wave transmission in optical materials under 1064 nm laser irradiation is the same with each other. The value of residual stress can be influenced by laser parameters and characterization of optical material. Simulation based on a theoretical model giving the residual stress field around a crack is developed for comparison with experiment results. The probability of initial damage and the direction of the energy dissipation in cracks determine the residual stress distribution. The thermal stress coupling enlarges the asymmetry of residual stress distribution. Residual stress in optical material has a strong effect on fracture and should be taken into account in any formulation that involves the enhanced damage resistance of optical components used in laser induced damage experiments.

  15. Residual stresses and durability in cold drawn eutectoid steel wires

    NASA Astrophysics Data System (ADS)

    Atienza, J. M.; Elices, M.; Ruiz-Hervias, J.; Caballero, L.; Valiente, A.

    2007-04-01

    Prestressing steel wires have excellent mechanical properties but there is a need to improve their durability in aggressive environments. In this work, the influence of residual stresses on the environmentally assisted cracking of these wires is studied. A good correlation has been found between residual stresses at the surface of the wires and the time to rupture during stress corrosion test proposed by the International Federation of Prestressing. Wires with the same microstructure, surface quality and mechanical properties show very different behaviour in aggressive environments depending on their residual stress state. Research shows that environmentally assisted cracking can be improved significantly by acting on the surface residual stresses produced by wire drawing. In addition, in this study a post-drawing treatment to generate compressive residual stresses at the surface of the wires is proposed.

  16. The effect of residual stress on photoluminescence in multi-crystalline silicon wafers

    NASA Astrophysics Data System (ADS)

    Pogue, Vanessa; Melkote, Shreyes N.; Rounsaville, Brian; Danyluk, Steven

    2017-02-01

    This paper presents the results of an experiment designed to understand the effect of manufacturing-induced residual stress on photoluminescence (PL) in multi-crystalline silicon (mc-Si) wafers used for photovoltaic applications. The experiment relies on the use of near-infrared birefringence polariscopy and polarized micro-Raman spectroscopy to measure casting-induced residual stress present in mc-Si wafers. High temperature annealing was used to relieve the residual stress in the mc-Si wafers, and photoluminescence was used to evaluate the electrical performance to provide a correlation of residual stress to electrical activity. High temperature annealing produced a drastic improvement in photoluminescence. A decrease in the number of points of highest maximum shear stress correlated with an increase in photoluminescence. Additionally, a direct correlation was found between higher tensile residual stress and increased PL.

  17. Modelling Of Residual Stresses Induced By High Speed Milling Process

    SciTech Connect

    Desmaison, Olivier; Mocellin, Katia; Jardin, Nicolas

    2011-05-04

    Maintenance processes used in heavy industries often include high speed milling operations. The reliability of the post-process material state has to be studied. Numerical simulation appears to be a very interesting way to supply an efficient residual stresses (RS) distribution prediction.Because the adiabatic shear band and the serrated chip shaping are features of the austenitic stainless steel high speed machining, a 2D high speed orthogonal cutting model is briefly presented. This finite element model, developed on Forge registered software, is based on data taken from Outeiro and al.'s paper [1]. A new behaviour law fully coupling Johnson-Cook's constitutive law and Latham and Cockcroft's damage model is detailed in this paper. It ensures results that fit those found in literature.Then, the numerical tools used on the 2D model are integrated to a 3D high speed milling model. Residual stresses distribution is analysed, on the surface and into the depth of the material. Various revolutions and passes of the two teeth hemispheric mill on the workpiece are simulated. Thus the sensitivity of the residual stresses generation to the cutting conditions can be discussed. In order to validate the 3D model, a comparison of the cutting forces measured by EDF R and D to those given by numerical simulations is achieved.

  18. Modelling Of Residual Stresses Induced By High Speed Milling Process

    NASA Astrophysics Data System (ADS)

    Desmaison, Olivier; Mocellin, Katia; Jardin, Nicolas

    2011-05-01

    Maintenance processes used in heavy industries often include high speed milling operations. The reliability of the post-process material state has to be studied. Numerical simulation appears to be a very interesting way to supply an efficient residual stresses (RS) distribution prediction. Because the adiabatic shear band and the serrated chip shaping are features of the austenitic stainless steel high speed machining, a 2D high speed orthogonal cutting model is briefly presented. This finite element model, developed on Forge® software, is based on data taken from Outeiro & al.'s paper [1]. A new behaviour law fully coupling Johnson-Cook's constitutive law and Latham and Cockcroft's damage model is detailed in this paper. It ensures results that fit those found in literature. Then, the numerical tools used on the 2D model are integrated to a 3D high speed milling model. Residual stresses distribution is analysed, on the surface and into the depth of the material. Various revolutions and passes of the two teeth hemispheric mill on the workpiece are simulated. Thus the sensitivity of the residual stresses generation to the cutting conditions can be discussed. In order to validate the 3D model, a comparison of the cutting forces measured by EDF R&D to those given by numerical simulations is achieved.

  19. Stress Measurement System

    NASA Technical Reports Server (NTRS)

    1996-01-01

    Under the Aircraft Structural Integrity program, Langley Research Center and Stress Photonics developed an infrared-based stress measurement system for use in nondestructive evaluation of materials and structures. Stress Photonics commercialized the technology in the DeltaTherm 1000 system, used to compare designs and detect cracks in structures, especially for aging aircraft and bridges. The system combines digital signal processing technology with a special infrared camera to provide instantaneous thermal images and live differential images.

  20. Thermoacoustic method for relaxation of residual stresses in welded joints

    SciTech Connect

    Koshovyi, V.V.; Pakhn`o, M.I.; Tsykhan, O.I.

    1995-01-01

    We propose a thermoacoustic method for the relaxation of residual stresses in welded joints, present a block diagram of a generator of local thermoacoustic pulses designed for implementation of this method, and describe our experiment aimed at relaxation of residual tensile stresses.

  1. Formation of the residual stress field under local thermal actions

    NASA Astrophysics Data System (ADS)

    Burenin, A. A.; Dats, E. P.; Murashkin, E. V.

    2014-03-01

    The one-dimensional process of material deformation due to local heating and subsequent cooling is analyzed in the framework of the classical theory of elastoplastic deformations. The problem of formation of residual stresses in a thin plate made of an elastoplastic material under a given thermal action is solved. The graphs of fields of residual stresses and displacements are constructed.

  2. Quantification of residual stress from photonic signatures of fused silica

    NASA Astrophysics Data System (ADS)

    Cramer, K. Elliott; Hayward, Maurice; Yost, William T.

    2014-02-01

    A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outer-most pane of Space Shuttle windows made from fused silica. A method and apparatus for calibration of the stress-optic coefficient using four-point bending is discussed. The results are validated on known material (acrylic) and are found to agree with literature values to within 6%. The calibration procedure is then applied to fused-silica specimens and the stress-optic coefficient is determined to be 2.43 ± 0.54 × 10-12 Pa-1. Fused silica specimens containing impacts artificially made at NASA's Hypervelocity Impact Technology Facility (HIT-F), to simulate damage typical during space flight, are examined. The damage sites are cored from fused silica window carcasses and examined with the GFP. The calibrated GFP measurements of residual stress patterns surrounding the damage sites are presented.

  3. Thermal Residual Stress in Environmental Barrier Coated Silicon Nitride - Modeled

    NASA Technical Reports Server (NTRS)

    Ali, Abdul-Aziz; Bhatt, Ramakrishna T.

    2009-01-01

    When exposed to combustion environments containing moisture both un-reinforced and fiber reinforced silicon based ceramic materials tend to undergo surface recession. To avoid surface recession environmental barrier coating systems are required. However, due to differences in the elastic and thermal properties of the substrate and the environmental barrier coating, thermal residual stresses can be generated in the coated substrate. Depending on their magnitude and nature thermal residual stresses can have significant influence on the strength and fracture behavior of coated substrates. To determine the maximum residual stresses developed during deposition of the coatings, a finite element model (FEM) was developed. Using this model, the thermal residual stresses were predicted in silicon nitride substrates coated with three environmental coating systems namely barium strontium aluminum silicate (BSAS), rare earth mono silicate (REMS) and earth mono di-silicate (REDS). A parametric study was also conducted to determine the influence of coating layer thickness and material parameters on thermal residual stress. Results indicate that z-direction stresses in all three systems are small and negligible, but maximum in-plane stresses can be significant depending on the composition of the constituent layer and the distance from the substrate. The BSAS and REDS systems show much lower thermal residual stresses than REMS system. Parametric analysis indicates that in each system, the thermal residual stresses can be decreased with decreasing the modulus and thickness of the coating.

  4. Residual stress determination of rail tread using a laser ultrasonic technique

    NASA Astrophysics Data System (ADS)

    Wang, Jing; Feng, Qibo

    2015-05-01

    A non-destructive method for measuring the residual stress on rail tread that uses a laser-generated ultrasonic technique is proposed. The residual stress distribution of different parts on both the new rail and used rail were examined. The surface acoustic waves (SAWs) are excited by a scanning line laser and detected by a laser ultrasonic detection system. A digital correlation method was used for calculating the changes in velocity of SAWs, which reflects the stress distribution. A wavelet de-noising technique and a least square fit were used for signal processing to improve the measurement accuracy. The effects of ultrasonic propagation distance and surface roughness on the determination of residual stress were analyzed and simulated. Results from the study demonstrate that the stress distribution results are accordant with the practical situation, and the laser-generated SAWs technique is a promising tool for the determination of residual stress in the railway inspection and other industrial testing fields.

  5. Residual stress and plastic anisotropy in indented 2024-T351 aluminum disks

    SciTech Connect

    Clausen, Bjorn; Prime, Michael B; Saurabh, Kabra; Brown, Donald W; Pagliaro, Pierluigi; Backlund, Peter; Shaw, Sanjiv; Criss, Everett

    2009-01-01

    Recent studies have proven that generating a well defined residual stress state using the indented disk approach is an excellent way to validate experimental and modeling techniques for measuring and predicting residual stresses. The previous studies dealt with indented stainless steel disks, and included experimental determination of residual stresses using the Contour Method and neutron diffraction measurements. The measured residual stress states showed good agreement between the techniques, and a Finite Element Model predicted residual stress state based upon material properties determined form standard tension and compression/tension tests was also in good agreement with the measurements. In the present work, disks of 2024-T351 Aluminum were investigated. As before, the residual stress profile was measured using neutron diffraction and the Contour Method and Finite Element Modeling was employed to predict the residual stress profile. Analysis and comparison of the three techniques were complicated by the fact that the experimental data shows evidence of plastic anisotropy and strong Bauschinger effect within the indented disks.

  6. Quantification of Residual Stress from Photonic Signatures of Fused Silica

    NASA Technical Reports Server (NTRS)

    Cramer, K. Elliott; Hayward, Maurice; Yost, William E.

    2013-01-01

    A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outer-most pane of Space Shuttle windows made from fused silica. A method and apparatus for calibration of the stress-optic coefficient using four-point bending is discussed. The results are validated on known material (acrylic) and are found to agree with literature values to within 6%. The calibration procedure is then applied to fused-silica specimens and the stress-optic coefficient is determined to be 2.43 +/- 0.54 x 10(exp -12)/Pa. Fused silica specimens containing impacts artificially made at NASA's Hypervelocity Impact Technology Facility (HIT-F), to simulate damage typical during space flight, are examined. The damage sites are cored from fused silica window carcasses and examined with the GFP. The calibrated GFP measurements of residual stress patterns surrounding the damage sites are presented. Keywords: Glass, fused silica, photoelasticity, residual stress

  7. Residual stress within nanoscale metallic multilayer systems during thermal cycling

    DOE PAGES

    Economy, David Ross; Cordill, Megan Jo; Payzant, E. Andrew; ...

    2015-09-21

    Projected applications for nanoscale metallic multilayers will include wide temperature ranges. Since film residual stress has been known to alter system reliability, stress development within new film structures with high interfacial densities should be characterized to identify potential long-term performance barriers. To understand factors contributing to thermal stress evolution within nanoscale metallic multilayers, stress in Cu/Nb systems adhered to Si substrates was calculated from curvature measurements collected during cycling between 25 °C and 400 °C. Additionally, stress within each type of component layers was calculated from shifts in the primary peak position from in-situ heated X-ray diffraction. The effects ofmore » both film architecture (layer thickness) and layer order in metallic multilayers were tracked and compared with monolithic Cu and Nb films. Analysis indicated that the thermoelastic slope of nanoscale metallic multilayer films depends on thermal expansion mismatch, elastic modulus of the components, and also interfacial density. The layer thickness (i.e. interfacial density) affected thermoelastic slope magnitude while layer order had minimal impact on stress responses after the initial thermal cycle. When comparing stress responses of monolithic Cu and Nb films to those of the Cu/Nb systems, the nanoscale metallic multilayers show a similar increase in stress above 200 °C to the Nb monolithic films, indicating that Nb components play a larger role in stress development than Cu. Local stress calculations from X-ray diffraction peak shifts collected during heating reveal that the component layers within a multilayer film respond similarly to their monolithic counterparts.« less

  8. Residual stress within nanoscale metallic multilayer systems during thermal cycling

    SciTech Connect

    Economy, David Ross; Cordill, Megan Jo; Payzant, E. Andrew; Kennedy, Marian S.

    2015-09-21

    Projected applications for nanoscale metallic multilayers will include wide temperature ranges. Since film residual stress has been known to alter system reliability, stress development within new film structures with high interfacial densities should be characterized to identify potential long-term performance barriers. To understand factors contributing to thermal stress evolution within nanoscale metallic multilayers, stress in Cu/Nb systems adhered to Si substrates was calculated from curvature measurements collected during cycling between 25 °C and 400 °C. Additionally, stress within each type of component layers was calculated from shifts in the primary peak position from in-situ heated X-ray diffraction. The effects of both film architecture (layer thickness) and layer order in metallic multilayers were tracked and compared with monolithic Cu and Nb films. Analysis indicated that the thermoelastic slope of nanoscale metallic multilayer films depends on thermal expansion mismatch, elastic modulus of the components, and also interfacial density. The layer thickness (i.e. interfacial density) affected thermoelastic slope magnitude while layer order had minimal impact on stress responses after the initial thermal cycle. When comparing stress responses of monolithic Cu and Nb films to those of the Cu/Nb systems, the nanoscale metallic multilayers show a similar increase in stress above 200 °C to the Nb monolithic films, indicating that Nb components play a larger role in stress development than Cu. Local stress calculations from X-ray diffraction peak shifts collected during heating reveal that the component layers within a multilayer film respond similarly to their monolithic counterparts.

  9. Nondestructive Testing Residual Stress Using Ultrasonic Critical Refracted Longitudinal Wave

    NASA Astrophysics Data System (ADS)

    Xu, Chunguang; Song, Wentao; Pan, Qinxue; Li, Huanxin; Liu, Shuai

    Residual stress has significant impacts on the performance of the mechanical components, especially on its strength, fatigue life and corrosion resistance and dimensional stability. Based on theory of acoustoelasticity, the testing principle of ultrasonic LCR wave method is analyzed. The testing system of residual stress is build. The method of calibration of stress coefficient is proposed in order to improve the detection precision. At last, through experiments and applications on residual stress testing of oil pipeline weld joint, vehicle's torsion shaft, glass and ceramics, gear tooth root, and so on, the result show that it deserved to be studied deeply on application and popularization of ultrasonic LCR wave method.

  10. The effect of residual stress on performance of high temperature coatings

    NASA Technical Reports Server (NTRS)

    1972-01-01

    Techniques for measurement of residual stress in MoSi2 coatings and the determination of stress in coatings prepared by metalliding, pack and slurry processes are discussed. The stress level can be determined by stress induced deflections or by X-ray techniques. The deflection method is most direct. It is based on the fact that a thin substrate, coated on one side only, is usually curved at room temperature. The radius of curvature is easily measured and readily related to residual stress.

  11. Method and apparatus for determination of material residual stress

    NASA Technical Reports Server (NTRS)

    Chern, Engmin J. (Inventor); Flom, Yury (Inventor)

    1993-01-01

    A device for the determination of residual stress in a material sample consisting of a sensor coil, adjacent to the material sample, whose resistance varies according to the amount of stress within the material sample, a mechanical push-pull machine for imparting a gradually increasing compressional and tensional force on the material sample, and an impedance gain/phase analyzer and personal computer (PC) for sending an input signal to and receiving an input signal from the sensor coil is presented. The PC will measure and record the change in resistance of the sensor coil and the corresponding amount of strain of the sample. The PC will then determine, from the measurements of change of resistance and corresponding strain of the sample, the point at which the resistance of the sensor coil is at a minimum and the corresponding value and type of strain of the sample at that minimum resistance point, thereby, enabling a calculation of the residual stress in the sample.

  12. Thermal evolution of residual stress in IN718 alloy subjected to laser peening

    NASA Astrophysics Data System (ADS)

    Xu, Suqiang; Huang, Shu; Meng, Xiankai; Sheng, Jie; Zhang, Haifeng; Zhou, Jianzhong

    2017-07-01

    The thermal relaxation behaviors of residual stresses induced by laser peening (LP) in IN718 alloy were investigated using an integrated numerical simulation and experimental approach. LP and heat treatments (HT) were carried out after which the X-ray diffraction (XRD) technique was employed in measuring the residual stresses. Micro-structures were observed using an optic microscope (OM) and transmission electron microscope (TEM). Dislocations induced by LP were also observed by TEM and characterized using the XRD technique. The effects of the applied temperature and the exposure time on residual stress and micro-structures were investigated. The results show that the extent of the residual stresses relaxation increased accordingly with the increase in the applied temperature. The relaxation rate was initially high and tended to stabilize for a longer exposure time. Grain size evolution during the process was subsequently discussed. Furthermore, a conceivable mechanism of residual stresses thermal relaxation behavior was obtained.

  13. Review of Ultrasonic Velocity Methods of Determining Residual Stress.

    DTIC Science & Technology

    1985-05-01

    Matzkanin and D.L. Davidson, The influence of mechanical stress on ’magnetization processes and Barkhausen Jumps in ferromagnetic materials. Int. Journ...AD-A160 769 REVIEM OF ULTRASONIC VELOCITY METHODS OF DETERMINING i I RESIDUAL STRESS (U) AERONAUTICAL RESEARCH LADS MELBOURNE I (AUSTRALIA) S J RUMBLE...RESEARCH LABORATORIES MELBOURNE, VICTORIA(0Io 0 Structurs Technical I8tDzandm 416 REVIE OF ULTRASONIC VELOCITY NETHODS OF DTLR1INING RESIDUAL STRESS

  14. Comparison of Residual Stress Distributions of Similar and Dissimilar Thick Butt-Weld Plates

    NASA Astrophysics Data System (ADS)

    Suzuki, Hiroshi; Katsuyama, Jinya; Morii, Yukio

    Residual stress distributions of 35 mm thick dissimilar metal butt-weld between A533B ferritic steel and Type 304 austenitic stainless steel (304SS) with Ni alloy welds and similar metal butt-weld of 304SS were measured using neutron diffraction. Effects of differences in thermal expansion coefficients (CTEs) and material strengths on the weld residual stress distributions were discussed by comparison of the residual stress distributions between the similar and dissimilar metal butt-welds. Residual stresses in the similar metal butt-weld exhibited typical distributions found in a thick butt-weld and they were distributed symmetrically on either side of the weld line. Meanwhile, asymmetric residual stress distributions were observed near the root of the dissimilar metal butt-weld, which was caused by differences in CTEs and yield strengths among both parent materials and weld metals. Transverse residual stress distribution of the dissimilar metal butt-weld was similar trend to that of the similar metal butt-weld, since effect of difference in CTEs were negligible, while magnitude of the transverse residual stress near the root depended on the yield strengths of each metal. In contrast, the normal and longitudinal residual stresses in the dissimilar metal butt-weld distributed asymmetrically on either side of weld line due to influence of differences in CTEs.

  15. WELD APPLICATION OF A NEW METHOD FOR CROSS-SECTIONAL RESIDUAL STRESS MAPPING

    SciTech Connect

    M. PRIME; ET AL

    2001-03-01

    The new ''contour method'' was used to measure a cross-sectional map of residual stresses in a welded plate. Comparisons with neutron diffraction measurements confirm the capability of the contour method to measure complex, 2-D stress maps. Compared to other methods, the contour method is relatively simple and inexpensive to perform, and the equipment required is widely available.

  16. Lamination residual stresses in hybrid composites, part 1

    NASA Technical Reports Server (NTRS)

    Daniel, I. M.; Liber, T.

    1976-01-01

    An experimental investigation was conducted to study lamination residual stresses for various material and loading parameters. The effects of hybridization on residual stresses and residual properties after thermal cycling under load were determined in angle-ply graphite/Kevlar/epoxy and graphite/S-glass/epoxy laminates. Residual strains in the graphite plies are not appreciably affected by the type and number of hybridizing plies. Computed residual stresses at room temperature in the S-glass plies reach values up to seventy-five percent of the transverse strength of the material. Computed residual stresses in the graphite plies exceed the static strength by approximately ten percent. In the case of Kevlar plies, computed residual stresses far exceed the static strength indicating possible early failure of these plies. Static testing of the hybrids above indicates that failure is governed by the ultimate strain of the graphite plies. In thermally cycled hybrids, in general, residual moduli were somewhat lower and residual strengths were higher than initial values.

  17. Effect of Residual Stresses on the Hardness of Bulk Metallic Glasses

    SciTech Connect

    Wang, L.; Bei, Hongbin; Gao, Y. F.; Lu, Zhao Ping; Nieh, T. G.

    2011-01-01

    Nanoindentation experiments were conducted on Zr-based metallic glass samples, which were elastically and plastically bent in order to investigate the effect of residual stresses on hardness. It was found that tensile residual stress reduced the hardness significantly, while compressive residual stress produced only a small effect on the hardness. These observations are consistent with three-dimensional continuum-plasticity-based finite-element simulations. The hardness was also found to vary more significantly with residual stresses, in particular in tension, than that caused by shear-banding-induced softening, suggesting hardness measurement is a practical method for the evaluation of tensile residual stresses in a metallic glass. Hardness variation in the bent sample was correlated with the residual-stress induced volume dilatation through a free-volume-based model. In this paper, we also present a detailed stress analysis based on yield asymmetry under tension and compression to describe the distribution of residual stresses in bent metallic glass specimens. The calculations agree well with the hardness variations measured experimentally.

  18. Effect of preheat on residual stress distributions in arc-welded mild steel plates

    SciTech Connect

    Adedayo, S.M.; Adeyemi, M.B.

    2000-02-01

    Residual stress distribution in the longitudinal and transverse directions on a 6-mm-thick arc-welded mild steel plate was experimentally examined with and without initial preheat. Stress measurements were completed by monitoring strain changes on mounted strain gauges resulting from successive milling of the welded plate specimens. Machining stresses were also compensated for by carrying out measurements of strain changes due to milling operation of a stress-free unwelded annealed mild steel plate. High tensile residual stresses exist close to the weld line in both longitudinal and transverse stresses. Maximum longitudinal residual stress values existing close to the weld line are reduced (between 50 and 75%) due to the effect of initial metal preheat of 200 C of the welded steel plate.

  19. Transient and residual stresses in dental porcelains as affected by cooling rates.

    PubMed

    Asaoka, K; Tesk, J A

    1989-06-01

    The development of either transient or residual stress in a slab of dental porcelain during cooling was simulated by use of a super-computer. The temperature dependences of the elastic modulus, the thermal expansion coefficient, and the shear viscosity, and the cooling rate dependence of the glass transition temperature, Tg, were considered in this calculation. Internal stress and viscoelastic creep were computed for several cooling rates. Calculated results display stress profiles which agree reasonably well with reported measured profiles in quenched, tempered glasses. The calculated residual surface stress, sigma, could be fit by the following empirical formula, sigma = kl2(q/q0)n, q is the cooling rate, q0 is a reference cooling rate and l is the half-thickness of the porcelain. The method by which residual stress develops is also discussed. This discussion suggests a method for strengthening of the porcelain by the development of high-compressive residual stress on the surface.

  20. Residual stresses and their effects in composite laminates

    NASA Technical Reports Server (NTRS)

    Hahn, H. T.; Hwang, D. G.

    1983-01-01

    Residual stresses in composite laminates are caused by the anisotropy in expansional properties of constituent unidirectional plies. The effect of these residual stresses on dimensional stability is studied through the warping of unsymmetric (0 sub 4/90 sub 4)sub T graphite/epoxy laminates while their effect on ply failure is analyzed for (0/90)sub 2s Kevlar 49/epoxy laminate. The classical laminated plate theory is used to predict the warping of small and large panels. The change of warping does not indicate a noticeable stress relaxation at 75 C while it is very sensitive to moisture content and hence to environment. A prolonged gellation at the initial cure temperature reduces residual stresses while postcure does not. The matrix/interface cracking in dry (0/90)sub 2s Kevlar 49/epoxy laminate is shown to be the result of the residual stress exceeding the transverse strength.

  1. Residual stresses in cross-ply composite tubes

    NASA Technical Reports Server (NTRS)

    Cohen, D.; Hyer, M. W.

    1984-01-01

    The residual thermal stresses in 4-layer cross-ply tubes are studied. The tubes considered has a small radius to wall-thickness ratios and so elasticity solutions were used. The residual thermal stress problem was considered to be axisymmetric and three elasticity solutions were derived and the results compared with the results using classical lamination theory. The comparison illustrates the limitations of classical lamination theory. The three elasticity solutions derived were: plane stress, plane strain, and generalized plane strain, the latter being the most realistic. Residual stresses in both the hoop and axial direction is significant. Stacking arrangement effects the residual stress to some extent, as do the material properties of the individual lamina. The benefits of hybrid construction are briefly discussed.

  2. Evaluation Of Residual Stresses In Inner Ring Of The Bearings

    NASA Astrophysics Data System (ADS)

    Malotová, Šárka; Hemžský, Pavel; Pitela, David; Nicielnik, Henryk; Šoková, Dagmar; Kyncl, Ladislav; Mrázik, Jozef

    2015-12-01

    Residual stresses are undesirable and it should not be underestimated. They occur in many components and it is necessary to identify and try to avoid them. For detection the Residual stresses, there are many methods, but not all are suitable, because they can completely destroy of the components. The article deals with the evaluation of Residual stresses in the inner rings of Bearings, which are made from steel 100Cr6 (ČSN 14 109.4. The surfaces were turning at different cutting parameters and subsequently are evaluated Residual stresses. The stresses have been evaluated by non - destructive method X - Ray. The experiment was realized in cooperation Faculty of Mechanical Engineering VSB - TU Ostrava and Faculty of Mechanical Engineering of ZU Zilina - machining in the laboratories of ZU Žilina, Slovak Republic.

  3. Residual stresses and their effects in composite laminates

    NASA Technical Reports Server (NTRS)

    Hahn, H. T.; Hwang, D. G.

    1983-01-01

    Residual stresses in composite laminates are caused by the anisotropy in expansional properties of constituent unidirectional plies. The effect of these residual stresses on dimensional stability is studied through the warping of unsymmetric (0 sub 4/90 sub 4)sub T graphite/epoxy laminates while their effect on ply failure is analyzed for (0/90)sub 2s Kevlar 49/epoxy laminate. The classical laminated plate theory is used to predict the warping of small and large panels. The change of warping does not indicate a noticeable stress relaxation at 75 C while it is very sensitive to moisture content and hence to environment. A prolonged gellation at the initial cure temperature reduces residual stresses while postcure does not. The matrix/interface cracking in dry (0/90)sub 2s Kevlar 49/epoxy laminate is shown to be the result of the residual stress exceeding the transverse strength.

  4. Residual stresses of sputtering titanium thin films at various substrate temperatures.

    PubMed

    Chang, R C; Chen, F Y; Chuang, C T; Tung, Y C

    2010-07-01

    This work seeks to characterize the residual stresses of titanium thin films as they are affected by various substrate temperatures during the sputtering process. The titanium thin films are deposited on silicon wafers by a RF magnetron sputter while different substrate temperatures are considered. The residual stresses are measured by both X-ray diffraction and a substrate curvature method, and consistent results are obtained by both methods. The results show that the residual stress decreases as the substrate temperature increases, in which the stress changes from tensile to compressive when the substrate temperature increases from 25 to 50 degrees C. Furthermore, the elastic modulus and hardness of the titanium thin films are tested with a nanoindenter using a standard Berkovich probe. Correlations between the residual stresses and mechanical properties measured by nanoindentation are also discussed.

  5. Optimization of machining and vibration parameters for residual stresses minimization in ultrasonic assisted turning of 4340 hardened steel.

    PubMed

    Sharma, Varun; Pandey, Pulak M

    2016-08-01

    The residual stresses generated in the machined work piece have detrimental effect on fatigue life, corrosion resistance and tribological properties. However, the effect of cutting and vibration parameters on residual stresses in Ultrasonic Assisted Turning (UAT) has not been dealt with. The present paper highlights the effect of feed rate, depth of cut, cutting velocity and percentage intensity of ultrasonic power on residual stress generation. XRD analysis has been carried out to measure the residual stress while turning 4340 hardened steel using UAT. The experiments were performed based on response surface methodology to develop statistical model for residual stress. The outcome of ANOVA revealed that percentage intensity and feed rate significantly affect the residual stress generation. The significant interactions between process parameters have also been presented tin order to understand the thermo-mechanical mechanism responsible for residual stress generation.

  6. Simulation on Residual Stress of Shot Peening Based on a Symmetrical Cell Model

    NASA Astrophysics Data System (ADS)

    WANG, Cheng; HU, Jiacheng; GU, Zhenbiao; XU, Yangjian; WANG, Xiaogui

    2017-03-01

    The symmetrical cell model is widely used to study the residual stress induced by shot peening. However, the correlation between the predicted residual stresses and the shot peening coverage, which is a big challenge for the researchers of the symmetrical cell model, is still not established. Based on the dynamic stresses and the residual stresses outputted from the symmetrical cell model, the residual stresses corresponding to full coverage are evaluated by normal distribution analysis. The predicted nodal dynamic stresses with respect to four corner points indicate that the equi-biaxial stress state exists only for the first shot impact. Along with the increase of shot number, the interactions of multiple shot impacts make the fluctuation of the nodal dynamic stresses about an almost identical value more and more obvious. The mean values and standard deviations of the residual stresses gradually tend to be stable with the increase of the number of shot peening series. The mean values at each corner point are almost the same after the third peening series, which means that an equi-biaxial stress state corresponding to the full coverage of shot peening is achieved. Therefore, the mean values of the nodal residual stresses with respect to a specific transverse cross-section below the peened surface can be used to correlate the measured data by X-ray. The predicted residual stress profile agrees with the experimental results very well under 200% peening coverage. An effective correlation method is proposed for the nodal residual stresses predicted by the symmetrical cell model and the shot peening coverage.

  7. Thermal Viscoelastic Analysis of Plastic Components Considering Residual Stress

    NASA Astrophysics Data System (ADS)

    Choi, Chel Woo; Jeoung, Kab Sik; Moon, Hyung-Il; Kim, Heon Young

    Plastics is commonly used in consumer electronics because of it is high strength per unit mass and good productivity, but plastic components may often become distorted after injection molding due to residual stress after the filling, packing, and cooling processes. In addition, plastic deteriorates depending on various temperature conditions and the operating time, which can be characterized by stress relaxation and creep. The viscoelastic behavior of plastic materials in the time domain can be expressed by the Prony series using the ABAQUS commercial software package. This paper suggests a process for predicting post-production deformation under cyclic thermal loading. The process was applied to real plastic panels, and the deformation predicted by the analysis was compared to that measured in actual testing, showing the possibility of using this process for predicting the post-production deformation of plastic products under thermal loading.

  8. Residual gravimetric method to measure nebulizer output.

    PubMed

    Vecellio None, Laurent; Grimbert, Daniel; Bordenave, Joelle; Benoit, Guy; Furet, Yves; Fauroux, Brigitte; Boissinot, Eric; De Monte, Michele; Lemarié, Etienne; Diot, Patrice

    2004-01-01

    The aim of this study was to assess a residual gravimetric method based on weighing dry filters to measure the aerosol output of nebulizers. This residual gravimetric method was compared to assay methods based on spectrophotometric measurement of terbutaline (Bricanyl, Astra Zeneca, France), high-performance liquid chromatography (HPLC) measurement of tobramycin (Tobi, Chiron, U.S.A.), and electrochemical measurements of NaF (as defined by the European standard). Two breath-enhanced jet nebulizers, one standard jet nebulizer, and one ultrasonic nebulizer were tested. Output produced by the residual gravimetric method was calculated by weighing the filters both before and after aerosol collection and by filter drying corrected by the proportion of drug contained in total solute mass. Output produced by the electrochemical, spectrophotometric, and HPLC methods was determined after assaying the drug extraction filter. The results demonstrated a strong correlation between the residual gravimetric method (x axis) and assay methods (y axis) in terms of drug mass output (y = 1.00 x -0.02, r(2) = 0.99, n = 27). We conclude that a residual gravimetric method based on dry filters, when validated for a particular agent, is an accurate way of measuring aerosol output.

  9. Numerical Simulation of Residual Stress in an Al-Cu Alloy Block During Quenching and Aging

    NASA Astrophysics Data System (ADS)

    Dong, Ya-Bo; Shao, Wen-Zhu; Lu, Liang-Xing; Jiang, Jian-Tang; Zhen, Liang

    2015-12-01

    In this study, residual stresses after different quenching and aging processes of Al-Cu forged blocks were investigated by numerical simulation method and experimental measurements. An iterative zone-based heat transfer calculation was coupled with the hyperbolic sine-type constitutive model to simulate the residual stress during quenching process. The simulation results were compared with experiment data using both x-ray diffraction and crack compliance methods. The simulation results were in good agreement with the experimental measurements with around 9-13% deviation at the largest. Residual stress reduction can be achieved by decreasing the cooling rate during quenching. Quenching in water with different temperatures of 60, 80, and 100 °C resulted in the maximum compressive residual stress reduction of approximately 28.2, 75.7, and 88.9%, respectively, in Al-Cu alloy samples. When quenched in 10, 20, and 30% PAG solution, the reduction of maximum compressive residual stress in Al-Cu alloy samples was approximately 35.1, 47.8, and 53.2%, respectively. In addition, in order to study the amount of residual stress relief after aging treatments, aging treatments at 140 and 170 °C for different times were also studied. Aging treatment used to obtain the peak-aged (T6) and overaged (T7) condition produces only about 22.5 to 34.7% reduction in residual stresses.

  10. Residual stresses in high-velocity oxy-fuel metallic coatings

    NASA Astrophysics Data System (ADS)

    Totemeier, T. C.; Wright, R. N.; Swank, W. D.

    2004-06-01

    X-ray based residual stress measurements were made on type 316 stainless steel and Fe3Al coatings that were high-velocity oxy-fuel (HVOF) sprayed onto low-carbon and stainless steel substrates. Nominal coating thicknesses varied from 250 to 1500 µm. The effect of HVOF spray particle velocity on residual stress and deposition efficiency was assessed by preparing coatings at three different torch chamber pressures. The effect of substrate thickness on residual stress was determined by spraying coatings onto thick (6.4 mm) and thin (1.4 mm) substrates. Residual stresses were compressive for both coating materials and increased in magnitude with spray velocity. For coatings applied to thick substrates, near-surface residual stresses were essentially constant with increasing coating thickness. Differences in thermal expansion coefficient between low-carbon and stainless steels led to a 180 MPa difference in residual stress for Fe3Al coatings. Deposition efficiency for both materials is maximized at an intermediate (˜600 m/s) velocity. Considerations for X-ray measurement of residual stresses in HVOF coatings are also presented.

  11. Power-law creep and residual stresses in carbopol microgels

    NASA Astrophysics Data System (ADS)

    Lidon, Pierre; Manneville, Sebastien

    We report on the interplay between creep and residual stresses in carbopol microgels. When a constant shear stress σ is applied below the yield stress σc, the strain is shown to increase as a power law of time, γ (t) =γ0 +(t / τ) α , with and exponent α ~= 0 . 38 that is strongly reminiscent of Andrade creep in hard solids. For applied shear stresses lower than some characteristic value of about σc / 10 , the microgels experience a more complex creep behavior that we link to the existence of residual stresses and to weak aging of the system after preshear. The influence of the preshear protocol, of boundary conditions and of microgel concentration on residual stresses is investigated. We discuss our results in light of previous works on colloidal glasses and other soft glassy systems.

  12. Residual stress in silicon wafer using IR polariscope

    NASA Astrophysics Data System (ADS)

    Lu, Zhijia; Wang, Pin; Asundi, Anand

    2008-09-01

    The infrared phase shift polariscope (IR-PSP) is a full-field optical technique for stress analysis in Silicon wafers. Phase shift polariscope is preferred to a conventional polariscope, as it can provide quantitative information of the normal stress difference and the shear stress in the specimen. The method is based on the principles of photoelasticity, in which stresses induces temporary birefringence in materials which can be quantitatively analyzed using a phase shift polariscope. Compared to other stress analysis techniques such as x-ray diffraction or laser scanning, infrared photoelastic stress analysis provides full-field information with high resolution and in near real time. As the semiconductor fabrication is advancing, larger wafers, thinner films and more compact packages are being manufactured. This results in a growing demand of process control. Residual stress exist in silicon during semiconductor fabrication and these stresses may make cell processing difficult or even cause the failure of the silicon. Reducing these stresses would improve manufacturability and reliability. Therefore stress analysis is essential to trace the root cause of the stresses. The polariscope images are processed using MATLAB and four-step phase shifting method to provide quantitative as well as qualitative information regarding the residual stress of the sample. The system is calibrated using four-point bend specimen and then the residual stress distribution in a MEMS sample is shown.

  13. A combined analytical and experimental approach to the determination of residual stresses in very thin cylindrical shells

    NASA Astrophysics Data System (ADS)

    Franco, Jamal Eli

    The residual stress in a high alloy ultra thin cylindrical shell is studied. The objective of this research is to quantify and develop an understanding of the residual stress produced during the fabrication process. It is shown, with the application of finite element analysis and experimental measurements, that the residual stress can be predicted and quantified. This dissertation investigates the experimental and numerical methods to determine the residual stress in high alloy ultra thin cylindrical shells. Experimental measurements of the shell profiles are used to obtain stresses during manufacturing. Finite element analysis is used to verify the experimental results. These results compare favorably with theoretical values. This dissertation shows that the thermal process applied to the shell for separation does not contribute to the residual stress. A residual stress due to the bending moment caused by the conical geometry of the shell is evident in the finite element results.

  14. Evaluation of Local Residual Stress Distribution of Stator Core in Rotating Machine

    NASA Astrophysics Data System (ADS)

    Kai, Yuichiro; Tsuchida, Yuji; Todaka, Takashi; Enokizono, Masato

    It is well known that magnetic properties deteriorate in constructed cores due to conditions stressed by riveting and welding during manufacturing process, punching and sharing in cutting process of the electrical steel sheets and so on. Therefore, it is important to know the relationships between the stress and magnetic property of the electrical steel in order to design the electrical machinery. In this paper, the local residual stress distribution on the cross section of the stator core in a rotating machine is measured with a X-ray stress measurement device. As the result, the difference of the residual stress distribution of each component is obtained in the teeth and core back of the stator core. In addition, we estimated the deterioration of the magnetic property in the teeth region. It was clarified that the magnetic properties of the electrical steel sheet is deteriorated due to the residual stress.

  15. Residual thermal stresses in composites for dimensionally stable spacecraft applications

    NASA Technical Reports Server (NTRS)

    Bowles, David E.; Tompkins, Stephen S.; Funk, Joan G.

    1992-01-01

    An overview of NASA LaRC's research on thermal residual stresses and their effect on the dimensional stability of carbon fiber reinforced polymer-matrix composites is presented. The data show that thermal residual stresses can induce damage in polymer matrix composites and significantly affect the dimensional stability of these composites by causing permanent residual strains and changes in CTE. The magnitude of these stresses is primarily controlled by the laminate configuration and the applied temperature change. The damage caused by thermal residual stresses initiates at the fiber/matrix interface and micromechanics level analyses are needed to accurately predict it. An increased understanding of fiber/matrix interface interactions appears to be the best approach for improving a composite's resistance to thermally induced damage.

  16. Residual thermal stresses in composites for dimensionally stable spacecraft applications

    NASA Technical Reports Server (NTRS)

    Bowles, David E.; Tompkins, Stephen S.; Funk, Joan G.

    1992-01-01

    An overview of NASA LaRC's research on thermal residual stresses and their effect on the dimensional stability of carbon fiber reinforced polymer-matrix composites is presented. The data show that thermal residual stresses can induce damage in polymer matrix composites and significantly affect the dimensional stability of these composites by causing permanent residual strains and changes in CTE. The magnitude of these stresses is primarily controlled by the laminate configuration and the applied temperature change. The damage caused by thermal residual stresses initiates at the fiber/matrix interface and micromechanics level analyses are needed to accurately predict it. An increased understanding of fiber/matrix interface interactions appears to be the best approach for improving a composite's resistance to thermally induced damage.

  17. Laser cutting of thick sheet metals: Residual stress analysis

    NASA Astrophysics Data System (ADS)

    Arif, A. F. M.; Yilbas, B. S.; Aleem, B. J. Abdul

    2009-04-01

    Laser cutting of tailored blanks from a thick mild steel sheet is considered. Temperature and stress field in the cutting sections are modeled using the finite element method. The residual stress developed in the cutting section is determined using the X-ray diffraction (XRD) technique and is compared with the predictions. The structural and morphological changes in the cut section are examined using the optical microscopy and scanning electron microscopy (SEM). It is found that temperature and von Mises stress increase sharply in the cutting section, particularly in the direction normal to the cutting direction. The residual stress remains high in the region close to the cutting section.

  18. THERMAL RESIDUAL STRESSES IN BILAYERED, TRILAYERED AND GRADED DENTAL CERAMICS.

    PubMed

    Fabris, Douglas; Souza, Júlio C M; Silva, Filipe S; Fredel, Márcio; Mesquita-Guimarães, Joana; Zhang, Yu; Henriques, Bruno

    2017-03-01

    Layered ceramic systems are usually hit by residual thermal stresses created during cooling from high processing temperature. The purpose of this study was to determine the thermal residual stresses at different ceramic multi-layered systems and evaluate their influence on the bending stress distribution. Finite elements method was used to evaluate the residual stresses in zirconia-porcelain and alumina-porcelain multi-layered discs and to simulate the 'piston-on-ring' test. Temperature-dependent material properties were used. Three different multi-layered designs were simulated: a conventional bilayered design; a trilayered design, with an intermediate composite layer with constant composition; and a graded design, with an intermediate layer with gradation of properties. Parameters such as the interlayer thickness and composition profiles were varied in the study. Alumina-porcelain discs present smaller residual stress than the zirconia-porcelain discs, regardless of the type of design. The homogeneous interlayer can yield a reduction of ~40% in thermal stress relative to bilayered systems. Thinner interlayers favoured the formation of lower thermal stresses. The graded discs showed the lowest thermal stresses for a gradation profile given by power law function with p=2. The bending stresses were significantly affected by the thermal stresses in the discs. The risk of failure for all-ceramic dental restorative systems can be significantly reduced by using trilayered systems (homogenous or graded interlayer) with the proper design.

  19. THERMAL RESIDUAL STRESSES IN BILAYERED, TRILAYERED AND GRADED DENTAL CERAMICS

    PubMed Central

    Fabris, Douglas; Souza, Júlio C.M.; Silva, Filipe S.; Fredel, Márcio; Mesquita-Guimarães, Joana; Zhang, Yu; Henriques, Bruno

    2017-01-01

    Layered ceramic systems are usually hit by residual thermal stresses created during cooling from high processing temperature. The purpose of this study was to determine the thermal residual stresses at different ceramic multi-layered systems and evaluate their influence on the bending stress distribution. Finite elements method was used to evaluate the residual stresses in zirconia-porcelain and alumina-porcelain multi-layered discs and to simulate the ‘piston-on-ring’ test. Temperature-dependent material properties were used. Three different multi-layered designs were simulated: a conventional bilayered design; a trilayered design, with an intermediate composite layer with constant composition; and a graded design, with an intermediate layer with gradation of properties. Parameters such as the interlayer thickness and composition profiles were varied in the study. Alumina-porcelain discs present smaller residual stress than the zirconia-porcelain discs, regardless of the type of design. The homogeneous interlayer can yield a reduction of ~40% in thermal stress relative to bilayered systems. Thinner interlayers favoured the formation of lower thermal stresses. The graded discs showed the lowest thermal stresses for a gradation profile given by power law function with p=2. The bending stresses were significantly affected by the thermal stresses in the discs. The risk of failure for all-ceramic dental restorative systems can be significantly reduced by using trilayered systems (homogenous or graded interlayer) with the proper design. PMID:28163345

  20. Method for residual stress relief and retained austenite destabilization

    DOEpatents

    Ludtka, Gerard M.

    2004-08-10

    A method using of a magnetic field to affect residual stress relief or phase transformations in a metallic material is disclosed. In a first aspect of the method, residual stress relief of a material is achieved at ambient temperatures by placing the material in a magnetic field. In a second aspect of the method, retained austenite stabilization is reversed in a ferrous alloy by applying a magnetic field to the alloy at ambient temperatures.

  1. Experimental Study of Residual Stresses in Metal Parts Obtained by Selective Laser Melting

    NASA Astrophysics Data System (ADS)

    Protasov, C. E.; Safronov, V. A.; Kotoban, D. V.; Gusarov, A. V.

    High local temperature gradients occur at additive manufacturing by selective laser melting of powder. This gives rise to undesirable residual stresses, deformations, and cracks. To understand how to control the formation of the residual stresses, a reliable method is necessary for measuring their distribution in the fabricated part. It is proposed to cut the part into thin plates and to reconstruct the residual stresses from the measured deformation of the plates. This method is tested on beams with square cross-section built from stainless steel. The beams were cut by electrical discharge machining and chemically etched. The obtained stress profile in vertical transversal direction slightly increases from the top to the bottom of the beam. This dependency is confirmed by numerical modeling. The measured stress profile agrees with the known results by other authors.

  2. The influence of alloy composition on residual stresses in heat treated aluminium alloys

    SciTech Connect

    Robinson, J.S.; Redington, W.

    2015-07-15

    The as quenched properties of eight different heat treatable aluminium alloys are related to residual stress magnitudes with the objective being to establish if there is a relationship between the residual stress and the as quenched alloy hardness and strength. Near surface residual stresses were assessed with X-ray diffraction using both the established sin{sup 2}ψ method and the more recent cos α technique. Through thickness residual stresses were also characterised using neutron diffraction. The alloys were chosen to encompass a wide range of strengths. The low to medium strength alloys were 6060 and 6082, medium to high strength 2618A, 2014A, 7075, 7010 and two variants of 7449, while the very high strength alloy was the powder metallurgy alloy N707. To assess the as quenched strength, dynamic hardness and tensile properties were determined from samples tested immediately after quenching to minimise the influence of precipitation hardening by natural aging. In addition, hot hardness measurements were made in situ on samples cooled to simulate quench paths. Within the experimental constraints of the investigation, the distribution of residual stress through the thickness was found to follow the same pattern for all the alloys investigated, varying from tensile in the interior to surface compression. The influence of alloy strength was manifested as a change in the observed residual stress magnitudes, and surface residual stresses were found to vary linearly with as quenched hardness and strength. - Highlights: • As quenched aluminium alloys contain high magnitude residual stresses. • Surface is compressive balance by a tensile core. • As quenched surface residual stress is linear function of alloy strength. • In situ hot hardness demonstrates rapid change in intrinsic hardness during rapid cooling.

  3. Pre and post machining and release residual stresses in microelectromechanical systems (MEMS)

    NASA Astrophysics Data System (ADS)

    Vechery, Mary; Dick, Andrew; Balachandran, B.; Dubey, Madan

    2008-03-01

    A major concern in the development of microelectromechanical systems (MEMS) is the presence of residual stress. This stress, which is produced during the fabrication of multi-layer thin-film structures, can significantly affect the performance of micro-scale devices. Though experimental measurement techniques are accurate, actual stress measurements can vary dramatically from run to run and wafer to wafer. For this reason, the modeling of this stress can be a challenging task. Past work has often focused on experimental, static techniques for determining residual-stress levels in single-layer and bi-layer structures. In addition, in prior studies, the focus has primarily been on residual-stress measurements in thin films as they are being deposited and prior to the release of a particular device. In this effort, residual stresses in MEMS resonators are characterized pre- and post-micro-machining and release of the structures. This is accomplished by applying three residual-stress identification techniques. The first technique, which is based on wafer-bow measurements and Stoney's formula, is suited for determining the residual stresses in thin film layers as they are being deposited and before the occurrence of a micro-machining or release process. In the second technique, a static parametric identification technique, device deflection data is made use of to approximate individual device residual stress immediately after release of a structure. The third technique, a dynamic parametric identification technique, which can be based on linear or nonlinear frequency response data can be used to estimate device residual stress immediately after release and after the device has been polarized. The results obtained by using these techniques are used to develop an understanding of how geometry, fabrication, release and polarization of resonators affect the stress state in a piezoelectric device. The results, which show that the stress levels can be quite different after a

  4. Quantifying Volcanic Stresses from Residual Stress Preserved in Magnetite and Zircon

    NASA Astrophysics Data System (ADS)

    Leonhardi, T. C.; Befus, K.; Manga, M.; Stan, C. V.; Tamura, N.

    2016-12-01

    Stresses active in volcanic systems are intimately linked with the processes driving magma chamber evolution and volcanic eruptions. These processes are difficult to quantify directly. Instead, insights come from a combination of modeling, geophysical observations, petrology and geochemistry. To directly quantify the forces and stresses associated with volcanic systems (such as chamber over-pressure) we need to develop techniques that provide new insights into volcanic processes. Here we quantified volcanic stresses in crystals from two units erupted from Yellowstone caldera. We used the Laue x-ray microdiffraction technique to measure preserved elastic lattice strain and the equivalent stress required to produce the strain. We analyzed zircon and magnetite crystals from pumice clasts in the pyroclastic fall deposit from the Tuff of Bluff Point and a flow front sample of the effusive Summit Lake lava flow. Analyses were performed using the x-ray microdiffraction beamline (12.3.2) at the Advanced Light Source, Lawrence Berkeley National Lab. Zircon preserved residual stress values in the range of 290-430 MPa for both units. Magnetite from the Tuff of Bluff Point preserves stress values of 310-370 MPa, whereas Summit Lake magnetite preserved values of 210-280 MPa. These values are greater that the estimates for lithostatic pressure in the final shallow storage chamber. If the values do represent the minerals' formation depth, then this indicates magnetite and zircon formed early in the magmatic system at greater depth. If true, residual stress in zircon and magnetite may be used as a crystallization geobarometer. Alternatively, if these values did not result from storage depth, they could reflect other processes in the chamber and conduit (such as fragmentation and thermal quenching). The observed differences in magnetite values suggest a change in the storage depth and/or volcanic stresses active in eruptions of the two deposits. For zircon, recoil damage and trace

  5. Residual Stresses and Critical Initial Flaw Size Analyses of Welds

    NASA Technical Reports Server (NTRS)

    Brust, Frederick W.; Raju, Ivatury, S.; Dawocke, David S.; Cheston, Derrick

    2009-01-01

    An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). A series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on the fatigue life. The purpose of the weld analyses was to model the weld process using a variety of sequences to determine the 'best' sequence in terms of weld residual stresses and distortions. The many factors examined in this study include weld design (single-V, double-V groove), weld sequence, boundary conditions, and material properties, among others. The results of this weld analysis are included with service loads to perform a fatigue and critical initial flaw size evaluation.

  6. Residual stresses and retained austenite distribution and evolution in SAE 52100 steel under rolling contact loading

    SciTech Connect

    Dommarco, R.C.; Kozaczek, K.J.; Hahn, G.T.

    1996-07-01

    Residual stresses are introduced and modified during manufacturing and also by normal use. In this paper the changes in magnitude and distribution of residual stresses, attending the strain induced transformation of retained austenite are examined. Tests were conducted on SAE 52100 bearing steel with different amounts of retained austenite in a 5-ball-rod rolling contact fatigue machine. The tests were accelerated by applying well-controlled micro- indentations on the wear track and using rough balls. The magnitude and distribution of residual stresses and retained austenite were measured using x-ray diffraction techniques. The contribution of the residual stresses and amount of retained austenite to the rolling contact fatigue life is analyzed.

  7. Residual stresses in angleplied laminates and their effects on laminate behavior

    NASA Technical Reports Server (NTRS)

    Chamis, C. C.

    1978-01-01

    Evidence of the presence of lamination residual stresses in angleplied laminates were transply cracks and warpage of unsymmetric laminates which occur prior to application of any mechanical load. Lamination residual strains were measured using the embedded strain gage technique. These strains result from the temperature differences between cure and room temperature and vary linearly within this temperature range. Lamination residual stresses were usually present in angleplied fiber composites laminates; they were also present in unidirectional hybrids and superhybrids. For specific applications, the magnitudes of lamination residual stresses were determined and evaluated relative to the anticipated applied stresses. Particular attention was given to cyclic thermal loadings in applications where the thermal cycling takes place over a wide temperature range.

  8. Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel

    SciTech Connect

    Outeiro, Jose C.; Pina, Jose C.; Umbrello, Domenico; Rizzuti, Stefania

    2007-05-17

    Residual stresses can enhance or impair the ability of a component to withstand loading conditions in service (fatigue, creep, stress corrosion cracking, etc.), depending on their nature: compressive or tensile, respectively. This poses enormous problems in structural assembly as this affects the structural integrity of the whole part. In addition, tool wear issues are of critical importance in manufacturing since these affect component quality, tool life and machining cost. Therefore, prediction and control of both tool wear and the residual stresses in machining are absolutely necessary. In this work, a two-dimensional Finite Element model using an implicit Lagrangian formulation with an automatic remeshing was applied to simulate the orthogonal cutting process of AISI H13 tool steel. To validate such model the predicted and experimentally measured chip geometry, cutting forces, temperatures, tool wear and residual stresses on the machined affected layers were compared. The proposed FE model allowed us to investigate the influence of tool geometry, cutting regime parameters and tool wear on residual stress distribution in the machined surface and subsurface of AISI H13 tool steel. The obtained results permit to conclude that in order to reduce the magnitude of surface residual stresses, the cutting speed should be increased, the uncut chip thickness (or feed) should be reduced and machining with honed tools having large cutting edge radii produce better results than chamfered tools. Moreover, increasing tool wear increases the magnitude of surface residual stresses.

  9. Residual Stress Analysis of Laser-Drilled Thermal Barrier Coatings Involving Various Bond Coats

    NASA Astrophysics Data System (ADS)

    Guinard, C.; Montay, G.; Guipont, V.; Jeandin, M.; Girardot, J.; Schneider, M.

    2015-01-01

    The gas turbine combustion chamber of aero-engines requires a thermal barrier coating (TBC) by thermal spraying. Further heat protection is achieved by laser drilling of cooling holes. The residual stresses play an important role in the mechanical behaviour of TBC. It could also affect the TBC response to delamination during laser drilling. In this work, studies of the cracking behaviour after laser drilling and residual stress distribution have been achieved for different bond coats by plasma spray or cold spray. From interface crack length measured pulse-by-pulse after laser percussion drilling at 20° angle, the role of the various bond coats on crack initiation and propagation are investigated. It is shown that the bond coat drastically influences the cracking behaviour. The residual stresses profiles were also determined by the incremental hole-drilling method involving speckle interferometry. An original method was also developed to measure the residual stress profiles around a pre-drilled zone with a laser beam at 90°. The results are discussed to highlight the influence of TBCs interfaces on the resulting residual stresses distribution before laser drilling, and also to investigate the modification around the hole after laser drilling. It is shown that laser drilling could affect the residual stress state.

  10. Quantification of residual stress from photonic signatures of fused silica

    SciTech Connect

    Cramer, K. Elliott; Yost, William T.; Hayward, Maurice

    2014-02-18

    A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outer-most pane of Space Shuttle windows made from fused silica. A method and apparatus for calibration of the stress-optic coefficient using four-point bending is discussed. The results are validated on known material (acrylic) and are found to agree with literature values to within 6%. The calibration procedure is then applied to fused-silica specimens and the stress-optic coefficient is determined to be 2.43 ± 0.54 × 10{sup −12} Pa{sup −1}. Fused silica specimens containing impacts artificially made at NASA’s Hypervelocity Impact Technology Facility (HIT-F), to simulate damage typical during space flight, are examined. The damage sites are cored from fused silica window carcasses and examined with the GFP. The calibrated GFP measurements of residual stress patterns surrounding the damage sites are presented.

  11. Gyrokinetic Simulation of Residual Stress from Diamagnetic Velocity Shears

    NASA Astrophysics Data System (ADS)

    Waltz, R. E.; Staebler, G. M.; Solomon, W. M.

    2010-11-01

    Residual stress refers to the remaining toroidal angular momentum (TAM) flux (divided by major radius) when the shear in the parallel velocity (and parallel velocity itself) vanishes. Previously [1] we demonstrated with gyrokinetic (GYRO) simulations that TAM pinching from the diamagnetic level shear in the ExB velocity could provide the residual stress needed for spontaneous toroidal rotation. Here we show that the shear in the diamagnetic velocities themselves provide comparable residual stress (and level of stabilization). The sign of the residual stress, quantified by the ratio of TAM flow to ion power flow (M/P), depends on the signs of the various velocity shears as well as ion (ITG) versus electron (TEM) mode directed turbulence. The residual stress from these temperature and density gradient diamagnetic velocity shears is demonstrated in global gyrokinetic simulation of ``null'' rotation DIIID discharges by matching M/P profiles within experimental error. 8pt [1] R.E. Waltz, G.M. Staebler, J. Candy, and F.L. Hinton, Phys. Plasmas 14, 122507 (2007); errata 16, 079902 (2009).

  12. The Correlation Between the Percussive Sound and the Residual Stress/Strain Distributions in a Cymbal

    NASA Astrophysics Data System (ADS)

    Osamura, Kozo; Kuratani, Fumiyasu; Koide, Toshio; Ogawa, Wataru; Taniguchi, Hiroyasu; Monju, Yoshiyuki; Mizuta, Taiji; Shobu, Takahisa

    2016-12-01

    The artistic sound of a cymbal is produced by employing a special copper alloy as well as incorporating complicated and heterogeneous residual stress/strain distributions. In order to establish a modern engineering process that achieves high-quality control for the cymbals, it is necessary to investigate the distribution of the residual stresses/strains in the cymbal and their quantitative relation with the frequency characteristics of the sound generated from the cymbal. In the present study, we have successfully used synchrotron radiation to measure the distribution of residual strain in two kinds of cymbals—after spinforming as well as after hammering. The microstructure and the mechanical properties of the cymbals were measured as well their acoustic response. Based on our experimental data, the inhomogeneous residual stress/strain distributions in the cymbals were deduced in detail and their influence on the frequency characteristics of the sound produced by the cymbals was identified.

  13. Experimental Investigation into the Effects of Weld Sequence and Fixture on Residual Stresses in Arc Welding Process

    NASA Astrophysics Data System (ADS)

    Kohandehghan, A. R.; Serajzadeh, S.

    2012-06-01

    This study concentrates on the effects of weld sequence and welding fixtures on distribution and magnitude of induced arc welding residual stresses built up in butt-joint of Gas Tungsten Arc Welding (GTAW) AA5251 plates. Aluminum plates have been welded under different welding conditions and then, longitudinal and transverse residual stresses were measured in different points of the welded plates employing hole-drilling technique. The results indicate that welding sequence significantly alters the distributions of both longitudinal and transverse residual stresses while the changing in the weld sequence leads to 44% decrease in longitudinal residual stress. Besides, both the geometry of weld pool and distribution of residual stresses are affected by the welding fixtures while implementation of fixture causes about 21 and 76% reductions in the depth of weld pool and transverse residual stress, respectively, for the material and welding conditions used in this research.

  14. Residual stresses in weld overlay tubes: A finite element study

    SciTech Connect

    Taljat, B.; Zacharia, T.; Wang, X.L.; Keiser, J.R.; Feng, Z.; Jirinec, M.J.

    1997-01-03

    Residual stresses and strains in a tube with circumferential weld overlay were analyzed by the finite element (FE) method. The objective of this work was to develop and verify a FE model, to determine the magnitude and distribution of residual stresses in the weld overlay tube, and to evaluate the significance of two contributing factors to residual stress: (1) difference in material properties between tube and weld material, and (2) thermal gradients in the weld. An axisymmetric FE model was developed to simulate the circumferential two-layer welding process of alloy 625 overlay on SA210 tube. The first layer was modeled as a gas metal arc welding process with filler metal, whereas the autogenous gas tungsten arc welding process was modeled for the second layer. Neutron diffraction technique was used to experimentally determine residual elastic strains in the weld overlay tube. Comparison with the FE results shows overall good agreement. Both the experimental and FE results show high compressive stresses at the inside tube surface and high tensile stresses in the weld overlay. This suggests that weld overlay may be used to relieve tensile or produce compressive stresses at the inside tube surface, which is significant for applications where crack initiation is found at the root pass of the joining weld.

  15. Optimum Injection Pressure of a Cavitating Jet for Introducing Compressive Residual Stress into Stainless Steel

    NASA Astrophysics Data System (ADS)

    Soyama, Hitoshi; Nagasaka, Kazuya; Takakuwa, Osamu; Naito, Akima

    Introducing compressive residual stress by a cavitating jet into the sub-surface of components used in nuclear power plants can mitigate stress corrosion cracking in these components. Although applying the jet is an effective method for this purpose, it should be used without causing damage to the surface from water jet droplets arising from high-pressure injection of the water jet. Thus, in introducing compressive residual stress, the injection pressure needs to be optimized. In this paper, in order to determine the optimum injection pressure, the residual stress of stainless steel treated by a jet at various injection pressures was measured using an X-ray diffraction method. The injection pressure of the jet was varied from 5 MPa to 300 MPa, and the diameter of the nozzle throat of the jet was varied from 0.35 mm to 2.0 mm. The variation of residual stress with depth was measured by alternating X-ray diffraction measurements with electropolishing. It was revealed that a cavitating jet at an injection pressure of 10 MPa with a nozzle diameter of 2.0 mm can introduce higher compressive residual stress to deeper into stainless steel compared with a jet at 300 MPa with a nozzle diameter of 0.35 mm when the downstream pressure of the nozzle was constant.

  16. Finite element calculation of residual stress in dental restorative material

    NASA Astrophysics Data System (ADS)

    Grassia, Luigi; D'Amore, Alberto

    2012-07-01

    A finite element methodology for residual stresses calculation in dental restorative materials is proposed. The material under concern is a multifunctional methacrylate-based composite for dental restorations, activated by visible light. Reaction kinetics, curing shrinkage, and viscoelastic relaxation functions were required as input data on a structural finite element solver. Post cure effects were considered in order to quantify the residual stresses coming out from natural contraction with respect to those debited to the chemical shrinkage. The analysis showed for a given test case that residual stresses frozen in the dental restoration at uniform temperature of 37°C are of the same order of magnitude of the strength of the dental composite material per se.

  17. Extension, inflation and torsion of a residually stressed circular cylindrical tube

    NASA Astrophysics Data System (ADS)

    Merodio, José; Ogden, Ray W.

    2016-03-01

    In this paper, we provide a new example of the solution of a finite deformation boundary-value problem for a residually stressed elastic body. Specifically, we analyse the problem of the combined extension, inflation and torsion of a circular cylindrical tube subject to radial and circumferential residual stresses and governed by a residual-stress dependent nonlinear elastic constitutive law. The problem is first of all formulated for a general elastic strain-energy function, and compact expressions in the form of integrals are obtained for the pressure, axial load and torsional moment required to maintain the given deformation. For two specific simple prototype strain-energy functions that include residual stress, the integrals are evaluated to give explicit closed-form expressions for the pressure, axial load and torsional moment. The dependence of these quantities on a measure of the radial strain is illustrated graphically for different values of the parameters (in dimensionless form) involved, in particular the tube thickness, the amount of torsion and the strength of the residual stress. The results for the two strain-energy functions are compared and also compared with results when there is no residual stress.

  18. Residual stress control by ion beam assisted deposition

    SciTech Connect

    Was, G.S.; Jones, J.W.; Parfitt, L.; Kalnas, C.E.; Goldiner, M.

    1996-12-31

    The origin of residual stresses were studied in both crystalline metallic films and amorphous oxide films made by ion beam assisted deposition (IBAD). Monolithic films of Al{sub 2}O{sub 3} were deposited during bombardment by Ne, Ar or Kr over a narrow range of energies, E, and a wide range of ion-to-atom arrival rate ratios, R and were characterized in terms of composition, thickness, density, crystallinity, microstructure and residual stress. The stress was a strong function of ion beam parameters and gas content and compares to the behavior of other amorphous compounds such as MoSi{sub x} and WSi{sub 2.2}. With increasing normalized energy (eV/atom), residual stress in crystalline metallic films (Mo, W) increases in the tensile direction before reversing and becoming compressive at high normalized energy. The origin of the stress is most likely due to densification or interstitial generation. Residual stress in amorphous films (Al{sub 2}O{sub 3}, MoSi{sub x} and WSi{sub 2.2}) is initially tensile and monotonically decreases into the compressive region with increasing normalized energy. The amorphous films also incorporate substantially more gas than crystalline films and in the case of Al{sub 2}O{sub 3} are characterized by a high density of voids. Stress due to gas pressure in existing voids explains neither the functional dependence on gas content nor the magnitude of the observed stress. A more likely explanation for the behavior of stress is gas incorporation into the matrix, where the amount of incorporated gas is controlled by trapping.

  19. On Taylor-Series Approximations of Residual Stress

    NASA Technical Reports Server (NTRS)

    Pruett, C. David

    1999-01-01

    Although subgrid-scale models of similarity type are insufficiently dissipative for practical applications to large-eddy simulation, in recently published a priori analyses, they perform remarkably well in the sense of correlating highly against exact residual stresses. Here, Taylor-series expansions of residual stress are exploited to explain the observed behavior and "success" of similarity models. Until very recently, little attention has been given to issues related to the convergence of such expansions. Here, we re-express the convergence criterion of Vasilyev [J. Comput. Phys., 146 (1998)] in terms of the transfer function and the wavenumber cutoff of the grid filter.

  20. Measurement of local stress for microelectronics applications

    NASA Astrophysics Data System (ADS)

    Zheng, Dawei

    For quality control and reliability analysis in semiconductor manufacturing, it is crucial to access the localized stress in devices due to process integration in thin film deposition, etching, passivation and thermal treatment. Presented in this dissertation is the exploration of a new methodology to access localized stress in patterned microstructures. It is called the "micro-bending-beam method". In order to evaluate the residual stress distribution in a thin film pattern residing on a silicon wafer, the Si underlying the pattern was thinned down uniformly so that its deflection, caused by the residual stress, could be measured. If the etched-back surface remains optically flat and reflective, then the bending of the diaphragm would be equivalent to its surface profile, which could be readily measured by a Twyman-Green laser interferometer. A procedure called "numerical etching" was implemented to simulate the Si etching process, which linked the stress state of the microstructure on a bulk wafer to that on a Si diaphragm. An initial stress field in the pattern was assumed, its effect on the bending of the Si diaphragm beneath was calculated and compared to the measured value. The discrepancy between them was used to modify the initially assumed stress field and repeated until satisfactory matches were achieved at each diaphragm thickness. The applicability of the micro-bending-beam method was demonstrated by resolving the residual stress in an electroless Ni bump. It was found that for a relatively thick diaphragm, the "plate" effect dominated; for a relatively thin diaphragm, the "membrane" effect dominated; at intermediate thickness, both effects existed. A general algorithm to solve non-linear equations where both bending stiffness and residual stress in a diaphragm must be considered was invented, and named "non-linear sequential analysis". It was found that for a pre-stressed pattern sitting on a stress-free Si diaphragm starting at to and thinned down to

  1. Effect of Treatment Area on Residual Stress and Fatigue in Laser Peened Aluminum Sheets

    NASA Astrophysics Data System (ADS)

    Toparli, M. Burak; Smyth, Niall; Fitzpatrick, Michael E.

    2017-01-01

    Two 2.0-mm-thick aluminum sheets were laser peened and the resulting residual stresses were measured using incremental hole drilling, surface X-ray diffraction, and synchrotron X-ray diffraction techniques. Laser peening was applied to two samples using the same laser peening parameters, but one of the samples has a larger peened area. The aim of this research was to discover the effect of peen area on residual stress, for application in aerospace structures for fatigue life enhancement. It was found that a larger peened area has higher and deeper compressive stresses in the crack-opening direction, leading to greater enhancement of fatigue life.

  2. Effect of Treatment Area on Residual Stress and Fatigue in Laser Peened Aluminum Sheets

    NASA Astrophysics Data System (ADS)

    Toparli, M. Burak; Smyth, Niall; Fitzpatrick, Michael E.

    2017-04-01

    Two 2.0-mm-thick aluminum sheets were laser peened and the resulting residual stresses were measured using incremental hole drilling, surface X-ray diffraction, and synchrotron X-ray diffraction techniques. Laser peening was applied to two samples using the same laser peening parameters, but one of the samples has a larger peened area. The aim of this research was to discover the effect of peen area on residual stress, for application in aerospace structures for fatigue life enhancement. It was found that a larger peened area has higher and deeper compressive stresses in the crack-opening direction, leading to greater enhancement of fatigue life.

  3. Experimental-Numerical Comparison of the Cantilever MEMS Frequency Shift in presence of a Residual Stress Gradient

    PubMed Central

    Ballestra, Alberto; Somà, Aurelio; Pavanello, Renato

    2008-01-01

    The dynamic characterization of a set of gold micro beams by electrostatic excitation in presence of residual stress gradient has been studied experimentally. A method to determine the micro-cantilever residual stress gradient by measuring the deflection and curvature and then identifying the residual stress model by means of frequency shift behaviour is presented. A comparison with different numerical FEM models and experimental results has been carried out, introducing in the model the residual stress of the structures, responsible for an initial upward curvature. Dynamic spectrum data are measured via optical interferometry and experimental frequency shift curves are obtained by increasing the dc voltage applied to the specimens. A good correspondence is pointed out between measures and numerical models so that the residual stress effect can be evaluated for different configurations. PMID:27879733

  4. JOINING OF MOLYBDENUM DISILICIDE TO STAINLESS STEEL USING AMORPHOUS METAL BRAZES-RESIDUAL STRESS ANALYSIS

    SciTech Connect

    VAIDYA, RAJENDRA U; KAUTZ, DOUGLAS D.; GALLEGOS, DAVID E.

    2007-01-30

    Molybdenum disilicide (MoSi{sub 2})/stainless steel 316 L jOints were produced by high temperature brazing using a cobalt-based metallic-glass (METGLAS{trademark} 2714A). Successful joining was completed in two different ways; either by feeding excess braze into the braze gap upon heating or by constraining the MoSi{sub 2}/stainiess steel assembly with an alumina (Al{sub 2}O{sub 3}) fixture during the heating cycle. These steps were necessary to ensure the production of a high quality void free joint. Residual stress measurements were completed on these joints. Indentation results show higher tensile residual stresses in the stainless steel for the joint with the external constraint, in comparison to the unconstrained state. In contrast, the compressive residual stresses In the MoSi{sub 2} (as measured by X-ray diffraction) were lower in the constrained state relative to the unconstrained state. These results and a lack of residual stress balance indicate that the stress state in the braze is significantly different under the two joining conditions and the volume of the braze plays an important role in the development of the residual stresses. Push-out tests carried out on these joints gave higher joint strengths in the unconstrained as compared to the constrained condition. The results of this study have important implications on the selection of the appropriate joining process (use of constraint versus extra braze).

  5. The Effect of Residual Stress on the Distortion of Gray Iron Brake Disks

    NASA Astrophysics Data System (ADS)

    Shin, M. W.; Jang, G. H.; Kim, J. K.; Kim, H. Y.; Jang, Ho

    2013-04-01

    Thermal distortion of gray iron brake disks due to residual stress and its effect on brake vibrations were studied. The residual stress of heat- and non-heat-treated gray iron disks was measured using neutron scattering. Dynamometer tests were performed to measure the friction force oscillation caused by the disk runout during brake applications. High-temperature tensile tests were carried out to find out possible plastic deformation due to residual stress during brake applications. The results showed that the average residual stress of the heat-treated disk (47.6 MPa) was lower than that of the non-heat-treated disk (99.6 MPa). Dynamometer tests at high temperatures (up to 600 °C) indicated that the residual stress pronounced the runout: the increase in disk runout after the tests for the non-heat-treated sample was more than twice that for the heat-treated sample. This difference correlated well with the neutron scattering results and the dimensional changes after a separate vacuum heat treatment. The high-temperature tensile tests showed severe reductions in yield strength at 600 °C, suggesting that disks produced with no stress relaxation could be deformed during severe braking.

  6. Residual stress characterization of steel TIG welds by neutron diffraction and by residual magnetic stray field mappings

    NASA Astrophysics Data System (ADS)

    Stegemann, Robert; Cabeza, Sandra; Lyamkin, Viktor; Bruno, Giovanni; Pittner, Andreas; Wimpory, Robert; Boin, Mirko; Kreutzbruck, Marc

    2017-03-01

    The residual stress distribution of tungsten inert gas welded S235JRC+C plates was determined by means of neutron diffraction (ND). Large longitudinal residual stresses with maxima around 600 MPa were found. With these results as reference, the evaluation of residual stress with high spatial resolution GMR (giant magneto resistance) sensors was discussed. The experiments performed indicate a correlation between changes in residual stresses (ND) and the normal component of local residual magnetic stray fields (GMR). Spatial variations in the magnetic field strength perpendicular to the welds are in the order of the magnetic field of the earth.

  7. The impact of the residual stress on the EUV pellicle

    NASA Astrophysics Data System (ADS)

    Park, Eun-Sang; Choi, Jae-Keun; Kim, Min-Ha; Hwang, Sollee; Shamsi, Zahid Hussain; Kim, Dai-Gyoung; Oh, Hye-Keun

    2016-05-01

    High resolution patterning on the chip could be achieved by extreme ultraviolet lithography (EUVL). However, the defect on the mask becomes more important issue with very short wavelength (13.5 nm). Using the pellicle which could protect the mask from the defects can support high volume manufacturing (HVM). Most of the materials considered for pellicle have relatively high extinction coefficient in EUV region. Therefore, the thickness of the pellicle should be ~ nm thin. The stress of the pellicle is dependent not only on the temperature but also on the mechanical properties of the pellicle. The stress induced by the gravity was small compared to the thermal stress. However, the residual stress should be also considered since it is dependent on the pellicle manufacturing environment and this stress is comparable with the thermal stress. Our result shows the importance of the lowering the pellicle fabrication temperature in terms of the extending the lifetime during the scanning process.

  8. Reduction of Residual Stress and Improvement of Dimensional Accuracy by Uphill Quenching for Al6061 Tube

    NASA Astrophysics Data System (ADS)

    Lim, Hak-Jin; Ko, Dae-Hoon; Ko, Dae-Cheol; Kim, Byung-Min

    2014-04-01

    The purpose of this study is to reduce the residual stress and machining distortion of an Al6061 tube by using uphill quenching. During uphill quenching, solid-solution heat-treated aluminum parts are usually immersed in LN2 at 77 K (-196 °C), followed by the rapid heating of the parts, to produce a new residual stress that is opposite in nature to the original. The uphill quenching method used in this study employed two types of heating methods: boiling water at 373 K (100 °C) and high-velocity steam at 448 K (175 °C). First, FE-simulation coupled with a CFD analysis was performed to predict the residual stress of the backward hot-extruded Al6061 tube with the following dimensions: Ø200 mm × h200 mm × t10 mm. Experiment of uphill quenching was also conducted to measure the residual stress using the boiling water and high-velocity steam uphill quenching methods. The predicted residual stresses were compared with the experimental results obtained via micro-indentation and saw-cutting tests, and a deviation of about 10.4 pct was found. In addition, the experimental results showed that uphill quenching could relieve up to 91 pct of the residual stress induced by water quenching. Finally, the dimensional accuracy of uphill quenched tubes was evaluated by measuring the roundness after the machining process, which showed that the uphill quenching method could improve the dimensional accuracy of an Al6061 tube by reducing the residual stress.

  9. Nondestructive evaluation of near-surface residual stress in shot-peened nickel-base superalloys

    NASA Astrophysics Data System (ADS)

    Yu, Feng

    Surface enhancement methods, which produce beneficial compressive residual stresses and increased hardness in a shallow near-surface region, are widely used in a number of industrial applications, including gas-turbine engines. Nondestructive evaluation of residual stress gradients in surface-enhanced materials has great significance for turbine engine component life extension and their reliability in service. It has been recently found that, in sharp contrast with most other materials, shot-peened nickel-base superalloys exhibit an apparent increase in electrical conductivity at increasing inspection frequencies, which can be exploited for nondestructive residual stress assessment. The primary goal of this research is to develop a quantitative eddy current method for nondestructive residual stress profiles in surface-treated nickel-base superalloys. Our work have been focused on five different aspects of this issue, namely, (i) validating the noncontacting eddy current technique for electroelastic coefficients calibration, (ii) developing inversion procedures for determining the subsurface residual stress profiles from the measured apparent eddy current conductivity (AECC), (iii) predicting the adverse effect of surface roughness on the eddy current characterization of shot-peened metals, (iv) separating excess AECC caused by the primary residual stress effect from intrinsic conductivity variations caused by material inhomogeneity, and (v) investigating different mechanisms through which cold work could influence the AECC in surface-treated nickel-base superalloys. The results of this dissertation have led to a better understanding of the underlying physical phenomenon of the measured excess AECC on nickel-base engine alloys, and solved a few critical applied issues in eddy current nondestructive residual stress assessment in surface-treated engine components and, ultimately, contributed to the better utilization and safer operation of the Air Force's aging

  10. Finite Element Simulation of Residual Stress Development in Thermally Sprayed Coatings

    NASA Astrophysics Data System (ADS)

    Elhoriny, Mohamed; Wenzelburger, Martin; Killinger, Andreas; Gadow, Rainer

    2017-04-01

    The coating buildup process of Al2O3/TiO2 ceramic powder deposited on stainless-steel substrate by atmospheric plasma spraying has been simulated by creating thermomechanical finite element models that utilize element death and birth techniques in ANSYS commercial software and self-developed codes. The simulation process starts with side-by-side deposition of coarse subparts of the ceramic layer until the entire coating is created. Simultaneously, the heat flow into the material, thermal deformation, and initial quenching stress are computed. The aim is to be able to predict—for the considered spray powder and substrate material—the development of residual stresses and to assess the risk of coating failure. The model allows the prediction of the heat flow, temperature profile, and residual stress development over time and position in the coating and substrate. The proposed models were successfully run and the results compared with actual residual stresses measured by the hole drilling method.

  11. Finite Element Simulation of Residual Stress Development in Thermally Sprayed Coatings

    NASA Astrophysics Data System (ADS)

    Elhoriny, Mohamed; Wenzelburger, Martin; Killinger, Andreas; Gadow, Rainer

    2017-03-01

    The coating buildup process of Al2O3/TiO2 ceramic powder deposited on stainless-steel substrate by atmospheric plasma spraying has been simulated by creating thermomechanical finite element models that utilize element death and birth techniques in ANSYS commercial software and self-developed codes. The simulation process starts with side-by-side deposition of coarse subparts of the ceramic layer until the entire coating is created. Simultaneously, the heat flow into the material, thermal deformation, and initial quenching stress are computed. The aim is to be able to predict—for the considered spray powder and substrate material—the development of residual stresses and to assess the risk of coating failure. The model allows the prediction of the heat flow, temperature profile, and residual stress development over time and position in the coating and substrate. The proposed models were successfully run and the results compared with actual residual stresses measured by the hole drilling method.

  12. Finite Element Modeling and Validation of Residual Stresses in 304 L Girth Welds

    SciTech Connect

    Dike, J.J.; Ortega, A.R.; Cadden, C.H.; Rangaswamy, P. Brown, D.

    1998-06-01

    Three dimensional finite element simulations of thermal and mechanical response of a 304 L stainless steel pipe subjected to a circumferential autogenous gas tungsten arc weld were used to predict residual stresses in the pipe. Energy is input into the thermal model using a volumetric heat source. Temperature histories from the thermal analysis are used as loads in the mechanical analyses. In the mechanical analyses, a state variable constitutive model was used to describe the material behavior. The model accounts for strain rate, temperature, and load path histories. The predicted stresses are compared with x-ray diffraction determinations of residual stress in the hoop and circumferential directions on the outside surface of the pipe. Calculated stress profiles fell within the measured data. Reasons for observed scatter in measured stresses are discussed.

  13. Hardness, Microstructure, and Residual Stresses in Low Carbon Steel Welding with Post-weld Heat Treatment and Temper Bead Welding

    NASA Astrophysics Data System (ADS)

    Aloraier, Abdulkareem S.; Joshi, Suraj; Price, John W. H.; Alawadhi, Khaled

    2014-04-01

    This paper investigates the effects of post-weld heat treatment (PWHT) and temper bead welding (TBW) on hardness, microstructure and residual stresses in multi-layer welding on low carbon steel specimens made with two different weld geometries, viz. (1) smooth-contoured and (2) U-shaped. It was found that the PWHT technique gave overall lower hardness than the TBW technique, but the hardness values in both techniques were acceptable. Microscopy analysis showed that the TBW technique was more effective in tempering the heat affected zone as the grain size decreased slightly at the fusion line in spite of the higher temperature at the fusion line. Residual stresses measured using the hole-drilling method showed that the residual stress is not reduced below yield stress near the last bead solidified in TBW. Only PWHT gives low residual stress results in this area. High tensile residual stresses may result in sensitivity to fatigue loading.

  14. Investigation of residual stresses in a multipass weld in 1 in. stainless steel plate

    NASA Astrophysics Data System (ADS)

    Spooner, S.; Fernandezbaca, J. A.; David, S. A.; Hubbard, C. R.; Holden, T. M.; Root, J. H.

    Residual stresses and strains were measured in two welded 25-mm thick plates of type 304 stainless steel by the neutron diffraction technique. The filler metal was type 308 stainless steel and the weld zone had a two phase microstructure in which the austenitic phase lattice parameter differs from the base metal. In these circumstances strain-free samples were taken from the weld zone area for analysis of the lattice parameters and ferrite content using neutron powder diffraction. Corrections for lattice parameter variation were applied permitting the calculation of residual strains and stresses in weld zone, heat affected zone (HAZ), and base metal. One of the two welds was examined without stress relief and the other was given a stress relief treatment consisting of vibration at a frequency below the resonant condition during welding. In both plates the largest residual stress component (longitudinal) is found in the fusion zone near the boundary between the weld zone and the heat affected zone. This longitudinal component is 400 +/- 50 MPa in tension. The normal stresses are generally close to zero although large fluctuations are found in the weld zone. The transverse stresses are as high as 200 MPa in the weld zone and decrease to 50 MPa +/- 40 MPa. The lattice parameter variation was equivalent to 5 x 10(exp -4) compressive strain and the ferrite content approached 9 percent at the center of the weld zone. Variations in residual stresses with thickness through the base metal plate were small. The treated plate and untreated plate showed nearly identical patterns of stress distribution. Differences in the measured stresses between vibratory-stress-relief treated and untreated plates fall within error bars of the stress determination in these particular 25 mm thick 300-type stainless steel plates.

  15. Mapping residual stresses after foreign object damage using the contour method

    SciTech Connect

    Prime, M. B.; Martineau, R. L.

    2002-01-01

    A 51-mm thick plate of High-Strength Low-Alloy (HSLA-100) steel was impacted by a 6.4 mm diameter tungsten carbide sphere traveling at 2.2 km/sec. The projectile penetration left a 10 mm diameter and 12 mm deep crater. A residual stress map over a cross-section through the crater was measured by the contour method. The predominant feature of the stress map was a peak compressive stress of 900 MPa, or 1.3 times the yield strength, centered about 1.5 crater radii below the crater floor. The results were compared with an explicit finite element simulation of the impact event. The model has good agreement with the measured residual stresses. As part of the study, residual stresses in the as-received HSLA-100 plate were also measured and found to be a typical quenching stress distribution with peak compressive stress of about 165 MPa a few mm below the surface and tensile stress of 200 MPa in the center of the plate thickness.

  16. Residual stresses in a shape welded steel tube by neutron diffraction

    NASA Astrophysics Data System (ADS)

    Taran, Yu V.; Balagurov, A. M.; Schreiber, J.; Stuhr, U.

    2008-03-01

    Measurements of the triaxial residual strains in a composite tube from an austenitic stainless steel as a parent material and a shape welded ferritic steel were carried out by the time-of-flight neutron diffraction method on the POLDI instrument at the PSI SINQ neutron pulsed facility. The shape weld is used to build compressive stresses and, as a result, to suppress stress corrosion. Investigations of the residual stresses in such composite tubes are important for developing optimal welding techniques. Calculation of the residual stresses was performed using measurement results with a comb-sample, machined from the tube by the electro-discharge method, as the stress free reference sample. The results of the POLDI measurements of the stress state in the composite tube are presented and compared to the results of the destructive turning out method and theoretical predictions of calculations by the finite element method. Semiquantitative agreement between all the used methods was only observed for the tangential component of the stress tensor. In this case, the ferrite cladding produced a tangential compressive stress of about 800 MPa on the austenitic tube.

  17. X-ray diffraction analysis of residual stress in zirconia dental composites

    NASA Astrophysics Data System (ADS)

    Allahkarami, Masoud

    Dental restoration ceramic is a complex system to be characterized. Beside its essential biocompatibility, and pleasant appearance, it requires being mechanically strong in a catastrophic loading environment. Any design is restricted with geometry boundary and material property limits. Inspired by natural teeth, a multilayer ceramic is a smart way of achieving an enhanced restoration. Bi-layers of zirconia core covered by porcelain are known as one of the best multilayer restorations. Residual stresses may be introduced into a bi-layer dental ceramic restoration during its entire manufacturing process due to thermal expansion and elastic property mismatch. It is impossible to achieve a free of residual stresses bi-layer zirconia-porcelain restoration. The idea is to take the advantage of residual stress in design in such a way to prevent the crack initiation and progression. The hypothesis is a compressive residual stress at external contact surface would be enabling the restoration to endure a greater tensile stress. Optimizing the layers thickness, manufacturing process, and validating 3D simulations require development of new techniques of thickness, residual stresses and phase transformation measurement. In the present work, a combined mirco-tomography and finite element based method were adapted for thickness measurement. Two new 2D X-ray diffraction based techniques were adapted for phase transformation area mapping and combined phase transformation and residual stress measurement. Concerning the complex geometry of crown, an efficient method for X-ray diffraction data collection mapping on a given curved surface was developed. Finally a novel method for 3D dimensional x-ray diffraction data collection and visualization were introduced.

  18. FEM simulation of residual stresses induced by laser Peening

    NASA Astrophysics Data System (ADS)

    Peyre, P.; Sollier, A.; Chaieb, I.; Berthe, L.; Bartnicki, E.; Braham, C.; Fabbro, R.

    2003-08-01

    Benefits from laser Peening have been demonstrated several times in fields like fatigue, wear or stress corrosion cracking. However, in spite of recent work on the calculation of residual stresses, very few authors have considered a finite element method (FEM) approach to predict laser-induced mechanical effect. This comes mainly from the high strain rates involved during LP (10^6 s^{-1}), that necessitate the precise determination of dynamic properties, and also from the possible combination of thermal and mechanical loadings in the case of LP without protective coatings. In this paper, we aim at presenting a global approach of the problem, starting from the determination of loading conditions and dynamic yield strengths, to finish with FEM calculation of residual stress fields induced on a 12% Cr martensitic stainless steel and a 7075 aluminium alloy.

  19. Nondestructive testing and characterization of residual stress field using an ultrasonic method

    NASA Astrophysics Data System (ADS)

    Song, Wentao; Xu, Chunguang; Pan, Qinxue; Song, Jianfeng

    2016-03-01

    To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel(12%C) as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave (LCR wave) is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.

  20. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

    SciTech Connect

    Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; Payzant, E. Andrew; Kolbus, Lindsay M.

    2015-09-08

    This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stir zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.

  1. Measurements of plutonium residues from recovery processes

    SciTech Connect

    Hsue, S.-T.; Langner, D.G.; Longmire, V.L.; Menlove, H.O.; Russo, P.A.; Sprinkle, J.K. Jr.

    1989-01-01

    Conventional methods of nondestructive assay (NDA) have accurately assayed the plutonium content of many forms of relatively pure and homogeneous bulk items. However, physical and chemical heterogeneities and the high and variable impurity levels of many categories of processing scrap bias the conventional NDA results. The materials also present a significant challenge to the assignment of reference values to process materials for purposes of evaluating the NDA methods. A recent study using impure, heterogeneous, pyrochemical residues from americium molten salt extraction (MSE) has been aimed at evaluating NDA assay methods based on conventional gamma-ray and neutron measurement techniques and enhanced with analyses designed to address the problems of heterogeneities and impurities. The study included a significant effort to obtain reference values for the MSE spent salts used in the study. Two of the improved NDA techniques, suitable for in-line assay of plutonium in bulk, show promise for timely in-process assays for one of the most difficult pyrochemical residues generated as well as for other impure heterogeneous scrap categories. 12 refs., 4 figs., 5 tabs.

  2. Impurity Effects on Momentum Transport and Residual Stress

    NASA Astrophysics Data System (ADS)

    Ko, Sehoon; Jhang, Hogun; Singh, R.

    2015-11-01

    Impurities are inevitable during tokamak plasma operation because of strong interaction of plasma and plasma facing component and helium ash as a byproduct of fusion process. They cause problems such as radiation power loss and fusion fuel dilution. On the other hands, they are used to diagnosis plasma parameters (CES, XICS etc) and to suppress edge-localized mode by wall-coating. In this research, we study the impact of impurities on turbulence driven intrinsic rotation (via residual stress) in the context of the quasi-linear theory. A two-fluid formulation for main and impurity ions is employed to study ion temperature gradient modes in sheared slab geometry modified by the presence of impurities. An effective form of the parallel Reynolds stress is derived in the center of mass frame of a coupled main ion-impurity system. Analyses show that the contents and the radial profile of impurities have a strong influence on the residual stress. In particular, an impurity profile aligned with that of main ions is shown to cause a considerable reduction of the residual stress, which may lead to the reduction of turbulence driven intrinsic rotation.

  3. Stress measurement with non-indentation

    SciTech Connect

    Jakus, K.; Evans, N.D.; Hay, J.C.

    1998-11-01

    The feasibility of using nano-indentation to measure residual stress in glasses was studied. Indents were placed on the side of flexure specimens at four different distances from the neutral axis while the specimens were under load in four-point-bending. Three different glasses (soda-lime, boro-silicate, and fused silica) were indented with a cube-corner indenter using 2 to 30 mN indentation loads. A high resolution scanning electron microscope was used to measure the length of the cracks emanating from the corners of the indents while the specimen remained under load. The measured crack lengths were correlated to the local stress using indentation theory. For the correlation, elastic beam theory was used to calculate the magnitude of the local stress at the indentation sites. Results derived from crack lengths were in good agreement with local stress within experimental scatter. However, this scatter was found to be rather large as a result of the stochastic nature of crack formation. It can be concluded from this study that nano-indentation can be used to measure residual surface stresses with high spatial resolution provided that a sufficient number of indents are used to assure good statistical accuracy.

  4. Investigation on Residual Stress Induced by Shot Peening

    NASA Astrophysics Data System (ADS)

    Zhao, Chunmei; Gao, Yukui; Guo, Jing; Wang, Qiang; Fu, Lichao; Yang, Qingxiang

    2015-03-01

    The high strength steel widely used in the aviation industry was chosen in this paper. The shot peening (SP) tests with different technical parameters were carried out, and compressive residual stress (CRS) distribution along the depth was determined. The phase structures before and after SP were analyzed by XRD and TEM. Microhardness and fatigue life were measured, and the morphology of fatigue fracture was also observed. The effects of different technical parameters on CRS field were investigated, and the CRS features with the characteristic parameters were analyzed deeply to summarize the rules. The results show that the CRS field induced by SP can be expressed by four characteristic parameters: the surface CRS σsrs, the maximum CRS σmrs, the depth of maximum CRS ξm and the depth of CRS (strengthened depth) ξ0. Martensite matrix is not changed by SP, while its boundary changes ambiguous with the formation of dislocations. After SP, the microhardness of the specimen increase, and the fatigue crack source moves inwards. The SP saturated time is 1 min. With the increase of SP intensity, σsrs, σmrs, ξm, and ξ0 all increase. While with the increase of SP angle, ξ0 grows gradually. The strengthen effect behaves more obviously as the shot size increases, and the shot material with larger hardness cause higher level of CRS field. Dual SP mainly increases σsrs value.

  5. Validating a Model for Welding Induced Residual Stress Using High-Energy X-ray Diffraction

    NASA Astrophysics Data System (ADS)

    Mach, J. C.; Budrow, C. J.; Pagan, D. C.; Ruff, J. P. C.; Park, J.-S.; Okasinski, J.; Beaudoin, A. J.; Miller, M. P.

    2017-03-01

    Integrated computational materials engineering (ICME) provides a pathway to advance performance in structures through the use of physically-based models to better understand how manufacturing processes influence product performance. As one particular challenge, consider that residual stresses induced in fabrication are pervasive and directly impact the life of structures. For ICME to be an effective strategy, it is essential that predictive capability be developed in conjunction with critical experiments. In the present work, simulation results from a multi-physics model for gas metal arc welding are evaluated through x-ray diffraction using synchrotron radiation. A test component was designed with intent to develop significant gradients in residual stress, be representative of real-world engineering application, yet remain tractable for finely spaced strain measurements with positioning equipment available at synchrotron facilities. The experimental validation lends confidence to model predictions, facilitating the explicit consideration of residual stress distribution in prediction of fatigue life.

  6. Validating a Model for Welding Induced Residual Stress Using High-Energy X-ray Diffraction

    NASA Astrophysics Data System (ADS)

    Mach, J. C.; Budrow, C. J.; Pagan, D. C.; Ruff, J. P. C.; Park, J.-S.; Okasinski, J.; Beaudoin, A. J.; Miller, M. P.

    2017-05-01

    Integrated computational materials engineering (ICME) provides a pathway to advance performance in structures through the use of physically-based models to better understand how manufacturing processes influence product performance. As one particular challenge, consider that residual stresses induced in fabrication are pervasive and directly impact the life of structures. For ICME to be an effective strategy, it is essential that predictive capability be developed in conjunction with critical experiments. In the present work, simulation results from a multi-physics model for gas metal arc welding are evaluated through x-ray diffraction using synchrotron radiation. A test component was designed with intent to develop significant gradients in residual stress, be representative of real-world engineering application, yet remain tractable for finely spaced strain measurements with positioning equipment available at synchrotron facilities. The experimental validation lends confidence to model predictions, facilitating the explicit consideration of residual stress distribution in prediction of fatigue life.

  7. Study of Residual Stress and Vacancy Defects in Oxide Dispersion Strengthened Steels

    NASA Astrophysics Data System (ADS)

    Slugeň, V.; Veterníková, J.; Kilpeläinen, S.; Tuomisto, F.

    This study was focused on commercial oxide-dispersion strengthened (ODS) steels -MA 956 (20%Cr), ODM 751 (16%Cr) and ODS Eurofer (9%Cr), developed for fuel cladding of GEN IV reactors. The ODS steels are described in order to comparison their microstructure features. Vacancy defects were observed by Doppler Broadening Spectroscopy (DBS) and Positron Annihilation Lifetime Spectroscopy (PALS). Residual stress proportional to all kinds of defects was investigated by Magnetic Barkhausen Noise (MBN) measurement. The positron techniques demonstrated the highest defect concentration for ODS Eurofer followed by MA 956. The lowest defect density belongs to ODM 751; although these defects are the largest (three or four vacancy clusters). MA 956 and ODS Eurofer have di-vacancies in predominance. MBN results are in a good accordance with positron techniques. The highest residual stress is for ODS Eurofer, followed by MA 956. Finally, the lowest residual stress proportional to hardness is found for ODM 751.

  8. Validating a Model for Welding Induced Residual Stress Using High-Energy X-ray Diffraction

    DOE PAGES

    Mach, J. C.; Budrow, C. J.; Pagan, D. C.; ...

    2017-03-15

    Integrated computational materials engineering (ICME) provides a pathway to advance performance in structures through the use of physically-based models to better understand how manufacturing processes influence product performance. As one particular challenge, consider that residual stresses induced in fabrication are pervasive and directly impact the life of structures. For ICME to be an effective strategy, it is essential that predictive capability be developed in conjunction with critical experiments. In the present paper, simulation results from a multi-physics model for gas metal arc welding are evaluated through x-ray diffraction using synchrotron radiation. A test component was designed with intent to developmore » significant gradients in residual stress, be representative of real-world engineering application, yet remain tractable for finely spaced strain measurements with positioning equipment available at synchrotron facilities. Finally, the experimental validation lends confidence to model predictions, facilitating the explicit consideration of residual stress distribution in prediction of fatigue life.« less

  9. Properties of low residual stress silicon oxynitrides used as a sacrificial layer

    SciTech Connect

    Habermehl, S.D.; Glenzinski, A.K.; Halliburton, W.M.; Sniegowski, J.J.

    2000-01-04

    Low residual stress silicon oxynitride thin films are investigated for use as a replacement for silicon dioxide (SiO{sub 2}) as sacrificial layer in surface micromachined microelectrical-mechanical systems (MEMS). It is observed that the level of residual stress in oxynitrides is a function of the nitrogen content in the film. MEMS film stacks are prepared using both SiO{sub 2} and oxynitride sacrificial layers. Wafer bow measurements indicate that wafers processed with oxynitride release layers are significantly flatter. Polycrystalline Si (poly-Si) cantilevers fabricated under the same conditions are observed to be flatter when processed with oxynitride rather than SiO{sub 2} sacrificial layers. These results are attributed to the lower post-processing residual stress of oxynitride compared to SiO{sub 2} and reduced thermal mismatch to poly-Si.

  10. The Sensitivity of Residual Stresses of Cross-Ply Laminates to Manufacturing and Material Parameters

    NASA Astrophysics Data System (ADS)

    Lahtinen, H.

    2003-01-01

    By using a finite-element model elaborated, the sensitivity of residual stresses of polyester/glass cross-ply laminates to manufacturing and material parameters is investigated. The development of residual stresses in the laminates and the significance of the parameters for the problem are discussed. It is found that the main attention in calculating residual stresses should be focused on the properties of resin, which must be measured with care. The most important parameters related to the resin are, of course, its stiffness, thermal expansion, and chemical shrinkage, while the properties of fibers can be obtained from material handbooks with a sufficient accuracy. In curing a thin laminate in an autoclave, the simulation of chemical reactions and the parameters needed in thermal analysis are quite insignificant, because, in practice, the autoclave temperature and the properties of the mold determine the laminate temperature history.

  11. Calculation of residual principal stresses in CVD boron on carbon filaments

    NASA Technical Reports Server (NTRS)

    Behrendt, D. R.

    1980-01-01

    A three-dimensional finite element model of the chemical vapor deposition (CVD) of boron on a carbon substrate (B/C) is developed. The model includes an expansion of the boron after deposition due to atomic rearrangement and includes creep of the boron and carbon. Curves are presented to show how the principal residual stresses and the filament elongation vary as the parameters defining deposition strain and creep are varied. The calculated results are compared with experimental axial residual stress and elongation measurements made on B/C filaments. This comparison requires that for good agreement between calculated and experimental results, the deposited boron must continue to expand after deposition, and that the build-up of residual stresses is limited by significant boron and carbon creep rates.

  12. Calculation of residual principal stresses in CVD boron on carbon filaments

    NASA Technical Reports Server (NTRS)

    Behrendt, D. R.

    1980-01-01

    A three-dimensional finite element model of the chemical vapor deposition of boron on a carbon substrate (B/C) is developed. The model includes an expansion of the boron after deposition due to atomic rearrangement and includes creep of the boron and carbon. Curves are presented showing the variation of the principal residual stresses and the filament elongation with the parameters defining deposition strain and creep. The calculated results are compared with experimental axial residual stress and elongation measurements made on B/C filaments. For good agreement between calculated and experimental results, the deposited boron must continue to expand after deposition, and the build up of residual stresses must be limited by significant boron and carbon creep rates.

  13. Stress Measurement by Geometrical Optics

    NASA Technical Reports Server (NTRS)

    Robinson, R. S.; Rossnagel, S. M.

    1986-01-01

    Fast, simple technique measures stresses in thin films. Sample disk bowed by stress into approximately spherical shape. Reflected image of disk magnified by amount related to curvature and, therefore, stress. Method requires sample substrate, such as cheap microscope cover slide, two mirrors, laser light beam, and screen.

  14. Lamination residual strains and stresses in hybrid laminates

    NASA Technical Reports Server (NTRS)

    Daniel, I. M.; Liber, T.

    1977-01-01

    An investigation is conducted of the effects of hybridization on the magnitude of lamination residual stresses. Eight-ply graphite/Kevlar 49/epoxy and graphite/S-glass/epoxy laminates were studied. The same matrix resin was selected for all basic materials to ensure compatibility and uniform curing of the various plies. The specimens, with inserted strain gages and thermocouples, were subjected to curing and postcuring cycles in an autoclave. Subsequently, the specimens were subjected to a thermal cycle from room temperature to 444 K and down to room temperature. It was found that hydridizing reduces apparently residual strains and stresses in the graphite plies. However, these strains were not affected much by the type and degree of hybridization.

  15. Residual strain change resulting from stress corrosion in Carrara marble

    NASA Astrophysics Data System (ADS)

    Voigtlaender, Anne; Leith, Kerry; Krautblatter, Michael

    2016-04-01

    Residual stresses and strains have been shown to play a fundamental role in determining the elastic behavior of engineering materials, yet the effect of these strains on brittle and elastic behavior of rocks remains unclear. In order to evaluate the impact of stored elastic strains on fracture propagation in rock, we undertook a four-month-long three-point bending test on three large 1100 x 100 x 100 mm Carrara Marble samples. This test induced stable low stress conditions in which strains were concentrated at the tip of a saw cut and pre-cracked notch. A corrosive environment was created at the tip of the notch on two samples (M2 and M4) by dripping calcite saturated water (pH ~ 7.5-8). Sample M5 was loaded in the same way, but kept dry. Samples were unloaded prior to failure, and along with an additional non-loaded reference sample (M0), cored into cylindrical subsamples (ø = 50 mm, h = 100 mm) before being tested for changes in residual elastic strains at the SALSA neutron diffractometer at the Institute Laue-Langevin (ILL), Grenoble, France. Three diffraction peaks corresponding to crystallographic planes hkl (110), (104) and (006) were measured in all three spatial directions relative to the notch. Shifts in the diffraction peak position (d) with respect to a strain free state are indicative of intergranular strain, while changes in the width of the peak (FWHM) reflect changes in intragranular strain. We observe distinctly different patterns in residual and volumetric strains in hkℓ (104) and (006) for the dry M5 and wet tested samples (M2 and M4) indicating the presence of water changes the deformation mechanism, while (110) is strained in compression around 200 μstrain in all samples. A broadening of the diffraction peaks (006) and (110) in front of the crack tip is observed in M2 and M4, while M5 shows no changes in the peak width throughout the depth of the sample. We suggest water present at the crack tip increased the rate of corrosion, allowing a

  16. Mechanical relaxation of localized residual stresses associatedwith foreign object damage

    SciTech Connect

    Boyce, B.L.; Chen, X.; Peters, J.O.; Hutchinson, J.H.; Ritchie,R.O.

    2002-05-01

    Foreign-object damage associated with the ingestion ofdebris into aircraft turbine engines can lead to a marked degradation inthe high-cycle fatigue life of turbine components. This degradation isgenerally considered to be associated with the premature initiation offatigue cracks at or near the damage sites; this is suspected to be dueto, at least in part, the impact-induced residual stress state, which canbe strongly tensile in these locations.

  17. In situ test structures for the thermal expansion coefficient and residual stress of polysilicon thin films

    NASA Astrophysics Data System (ADS)

    Liu, Hai-Yun; Li, Wei-Hua; Zhou, Zai-Fa; Huang, Qing-An

    2013-07-01

    In this research, micromachined devices consisting of four micro-rotating structures for the in situ determination of the thermal expansion coefficient (TEC), tensile and compressive residual stress of polysilicon thin films are studied. The structures are heated electrically and deflect due to the thermal expansion. The lateral displacements of the devices are related to the thermal stress and residual stress of the test beams. The micro-rotating structures are arranged, so that the lateral displacements are designed to be either a constant value which is used to determine the TEC of the thin film or a variable value that changes with the residual stress of the thin film. An analytical model of the test structure is presented. The finite element software ANSYS is used to verify the analytical model and provide guidelines for the structure design. Experimental results with a surface micromachined polysilicon thin film are used to demonstrate the proposed method. In the experiments, a current-voltage measurement system only is required. The TEC for the polysilicon thin film is obtained to be (2.61 ± 0.04) × 10-6 K-1 from 400 to 420 K and the residual stress is measured as -(10.15 ± 0.70) MPa.

  18. Measuring Environmental Stress

    ERIC Educational Resources Information Center

    Walker, John E.; Dahm, Douglas B.

    1975-01-01

    Infrared remote sensors, plus photometric interpretation and digital data analysis are being used to record the stresses on air, water, vegetation and soil. Directly recorded photographic information has been the most effective recording media for remote sensing. (BT)

  19. Measuring Environmental Stress

    ERIC Educational Resources Information Center

    Walker, John E.; Dahm, Douglas B.

    1975-01-01

    Infrared remote sensors, plus photometric interpretation and digital data analysis are being used to record the stresses on air, water, vegetation and soil. Directly recorded photographic information has been the most effective recording media for remote sensing. (BT)

  20. A new approach for the influence of residual stress on fatigue crack propagation

    NASA Astrophysics Data System (ADS)

    Zhu, Lin; Jia, Min-Ping

    Many manufacturing processes can induce residual stresses in produced components. These residual stresses influence the mean stress during cyclic loading. The initial residual stresses induced during manufacturing change during fatigue damage. This paper presents a research on the change of residual stress distribution during fatigue crack propagation; the research predicts crack propagation by considering residual stress. An analysis approach for the change in residual stress distribution is established according to the diffusion theory of cavity, which is also used to investigate cracks with different orientations. Experiments are conducted to verify the prediction results of residual stress. A probability density function based on Weibull distribution is established to evaluate the accuracy of predicted residual stress. The influence of residual stress on fatigue crack propagation is considered the effective stress intensity factor range, which is calculated under the combined stress field of applied stress and residual stress. An analysis model of crack propagation is established. Furthermore, the model of crack propagation is used to estimate the velocity of crack propagation for the cases, same as the cases of residual stress prediction. The case studies show that the results are basically identical with the experimental results, indicating that the proposed approach is acceptable.

  1. Estimation of the residual stresses in rails using electromagnetic-acoustic introduction-reception of waves

    NASA Astrophysics Data System (ADS)

    Murav'ev, V. V.; Volkova, L. V.; Gromov, V. E.; Glezer, A. M.

    2016-10-01

    An approach to estimating the residual stresses in rails using acoustoelasticity and electromagnetic-acoustic conversion is described. The results of ultrasonic control of the residual stresses in rail segments are presented.

  2. Pretension-Dependent Residual Stress of Alumina Fiber-Reinforced Composite Wire

    NASA Astrophysics Data System (ADS)

    Dai, Xiaoya; Zhang, Wenlong; Gao, Ping; Zhang, Shaozong; Gu, Mingyuan; Peng, Hua-Xin

    2013-11-01

    The relationship between pretension and residual stress of an aluminum wire reinforced with 45 vol pct continuous Nextel™ 610 alumina fibers is investigated. It is shown that as pretension stress increases, the matrix residual stress decreases. A transition in matrix residual stress from tension to compression occurs at a pretension stress of about 80 MPa. The initial rapidly decreased residual stress caused by pretension at relatively low pretension stresses is a result of matrix elastic compressive deformation; while the later gradually decreased residual stress at higher pretension stresses comes from matrix plastic compressive deformation. As the matrix yield stress and hardening exponent increase, the decrease in matrix residual stress with pretension stress is more rapid and the absolute value of matrix residual stress increases. An analytical model suitable for fiber-reinforced metal matrix composites (MMCs) with strong interfacial bonding is developed to describe the relationship between pretension and matrix residual stress and is shown to be in good agreement with the experimental and finite-element calculated results. The pretension-dependent matrix residual stress phenomenon suggests that the mechanical properties of fiber-reinforced MMCs associated with matrix residual stress may be effectively improved by applying tensile loads.

  3. Nondestructive evaluation of residual stress in short-fiber reinforced plastics by x-ray diffraction

    NASA Astrophysics Data System (ADS)

    Tanaka, Keisuke; Tokoro, Syouhei; Akiniwa, Yoshiaki; Egami, Noboru

    2014-06-01

    The X-ray diffraction method is used to measure the residual stress in injection-molded plates of short-fiber reinforced plastics (SFRP) made of crystalline thermoplastics, polyphenylene sulphide (PPS), reinforced by carbon fibers with 30 mass%. Based on the orientation of carbon fibers, injection molded plates can be modeled as three-layered lamella where the core layer is sandwiched by skin layers. The stress in the matrix in the skin layer was measured using Cr-Kα radiation with the sin2Ψ method. Since the X-ray penetration depth is shallow, the state of stresses measured by X-rays in FRP can be assumed to be plane stress. The X-ray measurement of stress in carbon fibers was not possible because of high texture. A new method was proposed to evaluate the macrostress in SFRP from the measurement of the matrix stress. According to micromechanics analysis of SFRP, the matrix stresses in the fiber direction, σ1m, and perpendicular to the fiber direction, σ2m, and shear stress τ12m can be expressed as the functions of the applied (macro-) stresses, σ1A, σ2A , τ12A as follows: σ1m = α11σ1A +α12σ2A, σ2m = α21σ1A + α22σ2A, τ12m = α66τ12A, where α11 ,α12, α21, α22, α66 are stress-partitioning coefficients. Using skin-layer strips cut parallel, perpendicular and 45° to the molding direction, the stress in the matrix was measured under the uniaxial applied stress and the stress-partitioning coefficients of the above equations were determined. Once these relations are established, the macrostress in SFRP can be determined from the measurements of the matrix stresses by X-rays.

  4. Investigation of Residual Stresses in a Hot Cured Glass Fibre Reinforced Epoxy Resin Composite

    DTIC Science & Technology

    1982-01-01

    to establish confidence in its use. Little work has been reported on the magnitudes of residual curing stresses and their effect on the performance...premature failure if the residual and service stresses are additive. Fbr accurate design work it is therefore essential to take residual curing stresses...used to evaluate the residual curing stresses in a liminated plate is given in Reference 2. The computer code developed in Reference 3 was used in this

  5. Cold Drawn Steel Wires-Processing, Residual Stresses and Ductility Part II: Synchrotron and Neutron Diffraction

    SciTech Connect

    Phelippeau,A.; Pommier, S.; Zakharchenko, I.; Levy-Tubiana, R.; Tsakalakos, T.; Clavel, M.; Croft, M.; Zhong, Z.; Prioul, C.

    2006-01-01

    Cold drawing of steel wires leads to an increase of their mechanical strength and to a drop in their ductility. The increase of their mechanical strength has long been related to the reduction of the various material scales by an intense plastic deformation. Besides, it was discussed in the companion paper that large plastic deformation leads to the loss of the material hardening capabilities and that, in such a case, residual stresses preserve the elongation to failure of wires. Experimental measurements of residual stresses inside the wire have therefore been undertaken. In this paper, lattice parameters as measured using synchrotron diffraction are compared with those calculated using the residual stress fields as determined by the finite-element method. There is a major disagreement between experimental and numerical results that is too large to be attributed to the errors of the finite-element analyses. Therefore, neutron diffraction experiments have also been performed. These measurements show that there is a significant variation of the lattice parameter with the drawing level, which is not inherited from residual stresses, and that variation is very sensitive to the cooling rate after processing. It is therefore proposed that cold drawing would induce a phase transformation of the steel, possibly a martensitic transformation.

  6. A wafer mapping technique for residual stress in surface micromachined films

    NASA Astrophysics Data System (ADS)

    Schiavone, G.; Murray, J.; Smith, S.; Desmulliez, M. P. Y.; Mount, A. R.; Walton, A. J.

    2016-09-01

    The design of MEMS devices employing movable structures is crucially dependant on the mechanical behaviour of the deposited materials. It is therefore important to be able to fully characterize the micromachined films and predict with confidence the mechanical properties of patterned structures. This paper presents a characterization technique that enables the residual stress in MEMS films to be mapped at the wafer level by using microstructures released by surface micromachining. These dedicated MEMS test structures and the associated measurement techniques are used to extract localized information on the strain and Young’s modulus of the film under investigation. The residual stress is then determined by numerically coupling this data with a finite element analysis of the structure. This paper illustrates the measurement routine and demonstrates it with a case study using electrochemically deposited alloys of nickel and iron, particularly prone to develop high levels of residual stress. The results show that the technique enables wafer mapping of film non-uniformities and identifies wafer-to-wafer differences. A comparison between the results obtained from the mapping technique and conventional wafer bow measurements highlights the benefits of using a procedure tailored to films that are non-uniform, patterned and surface-micromachined, as opposed to simple standard stress extraction methods. The presented technique reveals detailed information that is generally unexplored when using conventional stress extraction methods such as wafer bow measurements.

  7. Influence of Residual Stress Field on the Fatigue Crack Propagation in Prestressing Steel Wires

    PubMed Central

    Toribio, Jesús; Matos, Juan-Carlos; González, Beatriz; Escuadra, José

    2015-01-01

    This paper deals with the effect of several residual stress profiles on the fatigue crack propagation in prestressing steel wires subjected to tension loading or bending moment. To this end, a computer program was developed to evaluate the crack front evolution on the basis of the Walker law. Results demonstrate that the absence of residual stresses makes the crack propagate towards a preferential crack path. When surface residual stresses are tensile and, correspondingly, core residual stresses are compressive, the fatigue crack fronts rapidly converge towards a quasi-straight shape. When surface residual stresses are compressive, with their corresponding tensile stresses in the core area, a preferential crack path also appears. PMID:28793661

  8. Residual stress alleviation of aircraft metal structures reinforced with filamentary composites

    NASA Technical Reports Server (NTRS)

    Kelly, J. B.; June, R. R.

    1973-01-01

    Methods to eliminate or reduce residual stresses in aircraft metal structures reinforced by filamentary composites are discussed. Residual stress level reductions were achieved by modifying the manufacturing procedures used during adhesive bonding. The residual stress alleviation techniques involved various forms of mechanical constraint which were applied to the components during bonding. Nine methods were evaluated, covering a wide range in complexity. All methods investigated during the program affected the residual stress level. In general, residual stresses were reduced by 70 percent or more from the stress level produced by conventional adhesive bonding procedures.

  9. BOOK REVIEW: Analysis of Residual Stress by Diffraction Using Neutron and Synchrotron Radiation

    NASA Astrophysics Data System (ADS)

    Fitzpatrick, ed M. E.; Lodini, A.

    2003-09-01

    The presence of residual stresses within engineering components is often a key feature in determining their usable lifetimes and failure characteristics. Residual surface compression can, for example, restrict the propagation of surface cracks through the bulk. As a consequence, it is essential to characterize the magnitude and spatial distribution of residual stresses and, at least for non-destructive testing, this is most widely achieved using diffraction of neutron and high energy synchrotron radiations. This book aims to provide a detailed description of the methodology used to determine residual stresses. The major emphasis is placed on the neutron method, this being the more widely established approach at present. It contains 20 chapters contributed by 23 authors, divided into five major parts. The overall layout is very logical, with the first part giving a general introduction to the use of neutrons and x-rays for materials research and summarizing the methods used for their production. Part 2 considers the more specific aspects of extracting the residual stress distribution within a bulk sample and includes some valuable comments on a number of potential experimental problems, such as the determination of the stress-free lattice parameter and the effects of broadening of the Bragg peaks. The experimental facilities currently available or under development are described in part 3, with the remaining two parts devoted to general and specific applications of the residual stress measurement technique. As expected with such a large number of different authors, there is some variation in style and quality. However, the text is generally easy to follow and, more importantly, it is largely free of the problems of inconsistent notation and dupication of material that can afflict multi-authored texts. My only negative comment concerns the latter portion of the book devoted to specific applications of the technique, which is illustrative rather than comprehensive. In

  10. Residual stress inspection by Eu3+ photoluminescence piezo-spectroscopy: An application in thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Zhao, Yu; Ma, Chunli; Huang, Fengxian; Wang, Chunjie; Zhao, Sumei; Cui, Qiliang; Cao, Xueqiang; Li, Fangfei

    2013-08-01

    A non-destructive inspection technique was developed to measure the residual stresses in thermal barrier coatings (TBCs) by using Eu3+ photoluminescence piezo-spectroscopy. The new approach is based on the relationship between stress and the position of the main peak of 5D0→7F2 transition, which is built by the high-pressure techniques. The Eu3+ luminescent sublayer was applied in the current method to ensure that the detected position in TBCs can be well controlled. The laser used to detect Eu3+ luminescence gives a proper penetration depth and spatial resolution, which make this method suitable to detect the stresses concentrated near the interfaces between different layers. This method was successfully applied in detecting residual stress in plasma sprayed TBCs with a 8YSZ:Eu (1 mol. %) sublayer.

  11. Residual internal stress optimization for EPON 828/DEA thermoset resin using fiber Bragg grating sensors

    NASA Astrophysics Data System (ADS)

    Rohr, Garth D.; Rasberry, Roger D.; Kaczmarowski, Amy K.; Stavig, Mark E.; Gibson, Cory S.; Udd, Eric; Roach, Allen R.; Nation, Brendan

    2015-05-01

    Internal residual stresses and overall mechanical properties of thermoset resins are largely dictated by the curing process. It is well understood that fiber Bragg grating (FBG) sensors can be used to evaluate temperature and cure induced strain while embedded during curing. Herein, is an extension of this work whereby we use FBGs as a probe for minimizing the internal residual stress of an unfilled and filled Epon 828/DEA resin. Variables affecting stress including cure cycle, mold (release), and adhesion promoting additives will be discussed and stress measurements from a strain gauge pop-off test will be used as comparison. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration under contract DE-AC04-94AL85000.

  12. Enhancement of energy dispersive residual stress analysis by consideration of detector electronic effects

    NASA Astrophysics Data System (ADS)

    Denks, I. A.; Genzel, Ch.

    2007-08-01

    The effects of the germanium detector electronics on diffraction line patterns is investigated. It is shown that not only the detector resolution and the throughput but also the energy stability depend on both the specific detector settings and the dead time. For a moderate resolution versus throughput setting a correction function is proposed and applied to the near-surface residual stress analysis of three samples with considerably different stress states. It is demonstrated that without the correction function ghost stresses up to hundreds of MPa in the near-surface region are obtained. The correction procedure is verified by conventional X-ray measurements. In conclusion, the authors strongly suggest quantifying the electronic shifts of any individual detector systems prior to the analysis of residual stresses.

  13. Thermoelastic Residual Stresses and Deformations at Laser Treatment

    NASA Astrophysics Data System (ADS)

    Gusarov, A. V.; Malakhova-Ziablova, I. S.; Pavlov, M. D.

    A thermoelastic model implying relaxation of stresses at melting is applied for materials with arbitrary thermoelastic properties and the melting point. The range of Poisson's ratio 0.17 - 0.34 is numerically studied. The residual stresses are independent of the space scale. In narrow remelted zones and beads the maximum longitudinal tensile stress is approximately twice as high as the transverse one. The calculations predict cracking of alumina, even with 1600 oC preheating, plastic deformation or cracking of hard metal alloys H13 and TA6 V, and no destruction of polystyrene and thestrongest grades of quartz glass. The calculation results can be used for predicting the thermomechanical stability of materials at laser treatment.

  14. Phase composition and residual stresses in thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Lozovan, A. A.; Betsofen, S. Ya; Ashmarin, A. A.; Ryabenko, B. V.; Ivanova, S. V.

    2016-07-01

    X-ray study of the phase composition and residual stresses distribution in two-layer APS coatings showed that the ceramic layer consists of t-ZrO2 phase with tetragonal lattice and the metal underlayer γ-solid solution based on nickel. In the transition zone thickness of ∼ 100 pm as the distance from the surface was revealed a gradual transition from t-ZrO2 to γ-solid solution. Increase in the specific volume of the metal underlayer resulting TGO growing leads to the formation of this layer high compressive stresses up to 600 MPa. In this case, the ceramic layer contains tensile stress up to 200 MPa.

  15. Nondestructive Measurement of Bulk Residual Stresses.

    DTIC Science & Technology

    1983-10-01

    dcependence of the third- and the fourth- cider elast ic :ornstants. This result agrees with the experimental findings relating the tellipcra’ tUrC depende-nce...7alle (3). 1t CTr he see. that the pro- duct of the chazne iT, the enptralure dependence 9. Slama, k. and Ling. C. K., J. Appl . P ys. due tc apFlied...Ct N 00 11C- -1 -6 RL FLRENCLS 1. J. Lesse and A. E. Lord, Jr., J. Appl . Phys. 39, 3986 (1968). 2. N. Soga, J. Appl . Phys. 37, 3416 (1966). 5. 3

  16. Image-based Measurement of Post-Swallow Residue: The Normalized Residue Ratio Scale

    PubMed Central

    Pearson, William G.; Smith, Zachary M.; Steele, Catriona M.

    2012-01-01

    Post-swallow residue is considered a sign of swallowing impairment. Existing methods for capturing post-swallow residue (perceptual and quantitative) have inherent limitations. We employed several different perceptual and quantitative (ratio) methods for measuring post-swallow residue on the same 40 swallows and addressed the following questions: (1) Do perceptual and quantitative methods demonstrate good agreement? (2) What differences in precision are apparent by measurement method (one-dimensional, two-dimensional, and circumscribed area ratios)? (3) Do residue ratios agree strongly with residue area measures that are anatomically normalized? Based on the findings of this series of questions, a new method for capturing residue is proposed: the Normalized Residue Ratio Scale (NRRS). The NRRS is a continuous measurement that incorporates both the ratio of residue relative to the available pharyngeal space and the residue proportionate to the size of the individual. A demonstration of this method is presented to illustrate the added precision of the NRRS measurement in comparison to other approaches for measuring residue severity. PMID:23089830

  17. Microstructural residual stress in particle-filled dental composite.

    PubMed

    Prejzek, Ondřej; Spaniel, Miroslav; Mareš, Tomáš

    2015-01-01

    The main goal of this study is to develop a micromechanical model of a particle-filled dental composite focused on the residual stress (RS) field developed during the curing process in its microstructure. A finite element model of a representative volume element of filler and resin was developed, and volumetric shrinkage was simulated during the curing process. Four material models (von Mises plasticity model, Drucker-Prager plasticity model, von Mises plasticity model with stress relaxation and Drucker-Prager plasticity with stress relaxation) of the polymer resin were built to assess the influence of the material model on the resulting internal stress. The relationship between the curing process and the magnitude of the stress components will be described, and an analysis of the post-curing state of the material in particular microstructure locations will be conducted in this study. Obtained RS is comparable to the stresses developed in the material under the external load. The substantial dependence on the choice of material model for resin is to be observed, and the suitability of particular models is discussed.

  18. A study of evolution of residual stress in single crystal silicon electrode using Raman spectroscopy

    NASA Astrophysics Data System (ADS)

    Jana, M.; Singh, Raj N.

    2017-08-01

    Silicon is a promising anode material for lithium ion batteries. However, lithiation of silicon generates stress that is known to be the primary reason for the failure of the anode. This study explored the existence of residual stress in single crystalline silicon electrodes after full de-lithiation, i.e., under no mechanical or electrical load. The magnitude of residual stress and its evolution with the number of lithiation-delithiation cycles is measured by Raman spectroscopy and a simple mechanics based approach. It is shown that the residual stress is tensile in nature and increased from 69 ± 11 MPa after the 1st cycle to ˜291 ± 56 MPa after 50 cycles of lithiation and de-lithiation. Concurrently, microstructural studies were performed to demonstrate the consequence of the evolution of residual stress on failure by the fracture of the silicon anode. These results provide understanding on the progressive failure mechanism of single crystalline-based silicon electrodes upon lithiation-delithiation.

  19. Longitudinal residual strain and stress-strain relationship in rat small intestine.

    PubMed

    Dou, Yanling; Fan, Yanhua; Zhao, Jingbo; Gregersen, Hans

    2006-06-07

    To obtain a more detailed description of the stress-free state of the intestinal wall, longitudinal residual strain measurements are needed. Furthermore, data on longitudinal stress-strain relations in visceral organs are scarce. The present study aims to investigate the longitudinal residual strain and the longitudinal stress-strain relationship in the rat small intestine. The longitudinal zero-stress state was obtained by cutting tissue strips parallel to the longitudinal axis of the intestine. The longitudinal residual stress was characterized by a bending angle (unit: degrees per unit length and positive when bending outwards). Residual strain was computed from the change in dimensions between the zero-stress state and the no-load state. Longitudinal stresses and strains were computed from stretch experiments in the distal ileum at luminal pressures ranging from 0-4 cmH2O. Large morphometric variations were found between the duodenum and ileum with the largest wall thickness and wall area in the duodenum and the largest inner circumference and luminal area in the distal ileum (p < 0.001). The bending angle did not differ between the duodenum and ileum (p > 0.5). The longitudinal residual strain was tensile at the serosal surface and compressive at the mucosal surface. Hence, the neutral axis was approximately in the mid-wall. The longitudinal residual strain and the bending angle was not uniform around the intestinal circumference and had the highest values on the mesenteric sides (p < 0.001). The stress-strain curves fitted well to the mono-exponential function with determination coefficients above 0.96. The alpha constant increased with the pressure, indicating the intestinal wall became stiffer in longitudinal direction when pressurized. Large longitudinal residual strains reside in the small intestine and showed circumferential variation. This indicates that the tissue is not uniform and cannot be treated as a homogenous material. The longitudinal stiffness

  20. Longitudinal residual strain and stress-strain relationship in rat small intestine

    PubMed Central

    Dou, Yanling; Fan, Yanhua; Zhao, Jingbo; Gregersen, Hans

    2006-01-01

    Background To obtain a more detailed description of the stress-free state of the intestinal wall, longitudinal residual strain measurements are needed. Furthermore, data on longitudinal stress-strain relations in visceral organs are scarce. The present study aims to investigate the longitudinal residual strain and the longitudinal stress-strain relationship in the rat small intestine. Methods The longitudinal zero-stress state was obtained by cutting tissue strips parallel to the longitudinal axis of the intestine. The longitudinal residual stress was characterized by a bending angle (unit: degrees per unit length and positive when bending outwards). Residual strain was computed from the change in dimensions between the zero-stress state and the no-load state. Longitudinal stresses and strains were computed from stretch experiments in the distal ileum at luminal pressures ranging from 0–4 cmH2O. Results Large morphometric variations were found between the duodenum and ileum with the largest wall thickness and wall area in the duodenum and the largest inner circumference and luminal area in the distal ileum (p < 0.001). The bending angle did not differ between the duodenum and ileum (p > 0.5). The longitudinal residual strain was tensile at the serosal surface and compressive at the mucosal surface. Hence, the neutral axis was approximately in the mid-wall. The longitudinal residual strain and the bending angle was not uniform around the intestinal circumference and had the highest values on the mesenteric sides (p < 0.001). The stress-strain curves fitted well to the mono-exponential function with determination coefficients above 0.96. The α constant increased with the pressure, indicating the intestinal wall became stiffer in longitudinal direction when pressurized. Conclusion Large longitudinal residual strains reside in the small intestine and showed circumferential variation. This indicates that the tissue is not uniform and cannot be treated as a homogenous

  1. Nonlocal continuum crystal plasticity with internal residual stresses

    NASA Astrophysics Data System (ADS)

    Aghababaei, Ramin; Joshi, Shailendra P.; Reddy, J. N.

    2011-03-01

    We derive a three-dimensional constitutive theory accounting for length-scale dependent internal residual stresses in crystalline materials that develop due to a non-homogeneous spatial distribution of the excess dislocation (edge and screw) density. The second-order internal stress tensor is derived using the Beltrami stress function tensor φ that is related to the Nye dislocation density tensor. The formulation is derived explicitly in a three-dimensional continuum setting for elastically isotropic materials. The internal stresses appear as additional resolved shear stresses in the crystallographic visco-plastic constitutive law for individual slip systems. Using this formulation, we investigate two boundary value problems involving single crystals under symmetric double slip. In the first problem, the response of a geometrically imperfect specimen subjected to monotonic and cyclic loading is investigated. The internal stresses affect the overall strengthening and hardening under monotonic loading, which is mediated by the severity of initial imperfections. Such imperfections are common in miniaturized specimens in the form of tapered surfaces, fillets, fabrication induced damage, etc., which may produce strong gradients in an otherwise nominally homogeneous loading condition. Under cyclic loading the asymmetry in the tensile and compressive strengths due to this internal stress is also strongly influenced by the degree of imperfection. In the second example, we consider simple shear of a single crystalline lamella from a layered specimen. The lamella exhibits strengthening with decreasing thickness and increasing lattice incompatibility with shearing direction. However, as the thickness to internal length-scale ratio becomes small the strengthening saturates due to the saturation of the internal stress. Finally, we present the extension of this approach for crystalline materials exhibiting elastic anisotropy, which essentially depends on the appropriate Green

  2. Ares I-X Upper Stage Simulator Residual Stress Analysis

    NASA Technical Reports Server (NTRS)

    Raju, Ivatury S.; Brust, Frederick W.; Phillips, Dawn R.; Cheston, Derrick

    2008-01-01

    The structural analyses described in the present report were performed in support of the NASA Engineering and Safety Center (NESC) Critical Initial Flaw Size (CIFS) assessment for the Ares I-X Upper Stage Simulator (USS) common shell segment. An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. The results of this effort served as one of the critical load inputs required to perform a CIFS assessment of the same segment.

  3. Neutron diffraction investigation of residual stresses in transverse/oblique rail slices subjected to different grinding strategies

    SciTech Connect

    Gnaeupel-Herold, T.; Brand, P.C.; Prask, H.J.

    1999-05-01

    Using the Double Axis system for Residual stress, Texture, and Single crystal analysis (DARTS) at NIST, neutron diffraction residual stress measurements were carried out in the head region of five pairs of transverse and oblique cut slices of railroad track, each having a thickness of 6.35 mm. The slices were taken from a 300 HB rail of CFI 136 RE size. All slices except one unworn reference piece had the same accumulated tonnage but were ground in different intervals. The measurements confirm the results previously found which indicated the existence of high sub-surface residual tensile stresses, while the regional close to the wheel-rail contact line shows high residual compressive stresses.

  4. Residual stresses in a stainless steel - titanium alloy joint made with the explosive technique

    NASA Astrophysics Data System (ADS)

    Taran, Yu V.; Balagurov, A. M.; Sabirov, B. M.; Evans, A.; Davydov, V.; Venter, A. M.

    2012-02-01

    Joining of pipes from stainless steel (SS) and titanium (Ti) alloy still experience serious technical problems. Recently, reliable and hermetic joining of SS and Ti pipes has been achieved with the explosive bonding technique in the Russian Federal Nuclear Center. Such adapters are earmarked for use at the future International Linear Collider. The manufactured SS-Ti adapters have excellent mechanical behavior at room and liquid nitrogen temperatures, during high-pressure tests and thermal cycling. We here report the first neutron diffraction investigation of the residual stresses in a SS-Ti adapter on the POLDI instrument at the SINQ spallation source. The strain scanning across the adapter walls into the SS-SS and SS-Ti pipes sections encompassed measurement of the axial, radial and hoop strain components, which were transformed into residual stresses. The full stress information was successfully determined for the three steel pipes involved in the joint. The residual stresses do not exceed 300 MPa in magnitude. All stress components have tensile values close to the adapter internal surface, whilst they are compressive close to the outer surface. The strong incoherent and weak coherent neutron scattering cross-sections of Ti did not allow for the reliable determination of stresses inside the titanic pipe.

  5. Modeling and validation of residual stress distribution in an HSLA-100 disk

    SciTech Connect

    Feng, Z.; Zhu, Y.Y.; Zacharia, T.; Fields, R.J.; Prask, H.J.; Brand, P.C.; Blackburn, J.M.

    1995-12-31

    The residual stress distribution in a GTA spot we 100 steel disk was analyzed using thermomechanically uncoupled and semi-coupled finite element (FE) formulations and measured with the neutron diffraction technique. The computations used temperature-dependent the and mechanical properties of the base metal. The thermal analysis was based on the heat conduction formulation with the Gaussian heat input from the arc. The semi-coupled approach is an effective alternative to the fully coupled approach in which the incompatibility in the thermal and mechanical time increments often leads to numerical convergence difficulties. Convergence was achieved in the semi-coupled approach where a larger time increment for temperature calculation was automatically divided into some sub-intervals for the thermal stress calculation. The temperature, deformation configurations, and state variables were updated at the end of the temperature increment. The predictions from the FE models are in very good agreement with the neutron measurement results in the far heat-affected zone (HAZ) and in the base metal. Both models over-predicted the residual stress field in the fusion zone and near HAZ as measured by the neutron diffraction method. The discrepancy could be attributed to the changes in microstructures and material properties in the HAZ and fusion zone due to phase transformations during the welding thermal cycle. The formation of cracks in the fusion zone is another factor that possibly contributes to the lower measured residual stress values.

  6. Procedure for Computing Residual Stresses from Neutron Diffraction Data and its Application to Multi-Pass Dissimilar Weld

    SciTech Connect

    Zhang, Wei; Feng, Zhili; Crooker, Paul

    2011-01-01

    Neutron diffraction is a powerful tool for non-destructive measurement of internal residual stresses of welded structures. The conventional approach for determination of residual stresses requires the knowledge of stress-free lattice spacing a priori. For multiple-pass dissimilar metal welds common to nuclear reactor pipeline systems, the stress-free lattice parameter is a complex function of position due to the chemistry inhomogeneity in the weld region and can be challenging to determine experimentally. This paper presents a new approach to calculate the residual stress field in dissimilar welds without the use of stress-free lattice parameter. The theoretical basis takes advantage of the fact that the normal component of welding residual stresses is typically small for thin plate or pipe welds. The applicability of the new approach is examined and justified in a multi-pass dissimilar metal weld consisting of a stainless steel plate and a nickel alloy filler metal. The level of uncertainties associated with this new approach is assessed. Neutron diffraction experiment is carried out to measure the lattice spacing at various locations in the dissimilar weld. A comb-shaped specimen, electro-discharge machined from a companion weld, is used to determine the stress-free lattice spacing. The calculated results from the new approach are consistent with those from the conventional approach. The new approach is found to be a practical method for determining the two in-plane residual stress components in thin plate or pipe dissimilar metal welds.

  7. Residual stress distribution analysis of heat treated APS TBC using image based modelling.

    PubMed

    Li, Chun; Zhang, Xun; Chen, Ying; Carr, James; Jacques, Simon; Behnsen, Julia; di Michiel, Marco; Xiao, Ping; Cernik, Robert

    2017-08-01

    We carried out a residual stress distribution analysis in a APS TBC throughout the depth of the coatings. The samples were heat treated at 1150 °C for 190 h and the data analysis used image based modelling based on the real 3D images measured by Computed Tomography (CT). The stress distribution in several 2D slices from the 3D model is included in this paper as well as the stress distribution along several paths shown on the slices. Our analysis can explain the occurrence of the "jump" features near the interface between the top coat and the bond coat. These features in the residual stress distribution trend were measured (as a function of depth) by high-energy synchrotron XRD (as shown in our related research article entitled 'Understanding the Residual Stress Distribution through the Thickness of Atmosphere Plasma Sprayed (APS) Thermal Barrier Coatings (TBCs) by high energy Synchrotron XRD; Digital Image Correlation (DIC) and Image Based Modelling') (Li et al., 2017) [1].

  8. SCC of 2304 Duplex Stainless Steel—Microstructure, Residual Stress and Surface Grinding Effects

    PubMed Central

    Zhou, Nian; Peng, Ru Lin; Schönning, Mikael; Pettersson, Rachel

    2017-01-01

    The influence of surface grinding and microstructure on chloride induced stress corrosion cracking (SCC) behavior of 2304 duplex stainless steel has been investigated. Grinding operations were performed both parallel and perpendicular to the rolling direction of the material. SCC tests were conducted in boiling magnesium chloride according to ASTM G36; specimens were exposed both without external loading and with varied levels of four-point bend loading. Residual stresses were measured on selected specimens before and after exposure using the X-ray diffraction technique. In addition, in-situ surface stress measurements subjected to four-point bend loading were performed to evaluate the deviation between the actual applied loading and the calculated values according to ASTM G39. Micro-cracks, initiated by grinding induced surface tensile residual stresses, were observed for all the ground specimens but not on the as-delivered surfaces. Loading transverse to the rolling direction of the material increased the susceptibility to chloride induced SCC. Grinding induced tensile residual stresses and micro-notches in the as-ground surface topography were also detrimental. PMID:28772582

  9. SCC of 2304 Duplex Stainless Steel-Microstructure, Residual Stress and Surface Grinding Effects.

    PubMed

    Zhou, Nian; Peng, Ru Lin; Schönning, Mikael; Pettersson, Rachel

    2017-02-23

    The influence of surface grinding and microstructure on chloride induced stress corrosion cracking (SCC) behavior of 2304 duplex stainless steel has been investigated. Grinding operations were performed both parallel and perpendicular to the rolling direction of the material. SCC tests were conducted in boiling magnesium chloride according to ASTM G36; specimens were exposed both without external loading and with varied levels of four-point bend loading. Residual stresses were measured on selected specimens before and after exposure using the X-ray diffraction technique. In addition, in-situ surface stress measurements subjected to four-point bend loading were performed to evaluate the deviation between the actual applied loading and the calculated values according to ASTM G39. Micro-cracks, initiated by grinding induced surface tensile residual stresses, were observed for all the ground specimens but not on the as-delivered surfaces. Loading transverse to the rolling direction of the material increased the susceptibility to chloride induced SCC. Grinding induced tensile residual stresses and micro-notches in the as-ground surface topography were also detrimental.

  10. High-Temperature Deformation Constitutive Law for Dissimilar Weld Residual Stress Modeling: Effect of Thermal Load on Strain Hardening

    SciTech Connect

    Yu, Xinghua; Wang, Yanli; Crooker, Paul; Feng, Zhili

    2015-01-01

    Weld residual stress is one of the primary driving forces for primary water stress corrosion cracking in dissimilar metal welds (DMWs). To mitigate tensile residual stress in DMWs, it is critical to understand residual stress distribution by modeling techniques. Recent studies have shown that weld residual stress prediction using today s DMW residual stress models strongly depends on the strain-hardening constitutive model chosen. The commonly used strain-hardening models (isotropic, kinematic, and mixed) are all time-independent and inadequate to account for the time-dependent (viscous) plastic deformation at the elevated temperatures experienced during welding. For materials with profound strain-hardening, such as stainless steels and nickel-based alloys that are widely used in nuclear reactor and piping systems, the equivalent plastic strain the determinate factor of the flow stress can be highly dependent on the recovery and recrystallization processes. These processes are in turn a strong function of temperature, time, and deformation rate. Recently, the authors proposed a new temperature- and time-dependent strain-hardening constitutive model: the dynamic strain-hardening constitutive model. The application of such a model has resulted in improved weld residual stress prediction compared to the residual stress measurement results from the contour and deep-hole drilling methods. In this study, the dynamic strain-hardening behavior of Type 304 stainless steel and Alloy 82 used in pressure vessel nozzle DMWs is experimentally determined. The kinetics of the recovery and recrystallization of flow stress are derived from experiments, resulting in a semi-empirical equation as a function of pre-strain, time, and temperature that can be used for weld residual stress modeling. The method used in this work also provides an approach to study the kinetics of recovery and recrystallization of other materials with significant strain-hardening.

  11. Research opportunities and facilities at ORNL`s residual stress user center

    SciTech Connect

    Hubbard, C.R.; Watkins, T.R.; Kozaczek, K.; Wang, X.-L.; Spooner, S.

    1994-09-01

    The High Temperature Materials Laboratory (HTML) User Program at ORNL was established to help solve high-temperature materials problems that limit the efficiency and reliability of advanced energy-conversion systems. Both proprietary and nonproprietary research can be conducted within the user program. The facilities are open to researchers in US industry, universities, and federal laboratories. The Residual Stress User Center (RSUC), one of the six HTML user centers, was recently established and consists of two high precision x-ray diffraction systems for measurement of residual strain and texture. Both biaxial and triaxial residual strain data can be collected. Attachments to the diffraction system include a position sensitive detector and a laser specimen positioning system. The RSUC has capabilities for electropolishing and strain measurement with strain gauges. A complementary neutron diffraction facility has recently been developed and demonstrated at the High Flux Isotope Reactor at ORNL. The neutron diffraction facility enables mapping of macro residual stresses throughout the volume of a component, complementing the near surface stress measurements available by x-ray diffraction. The neutron facility has been proposed as an addition to the RSUC.

  12. Residual stresses in particulate and short fiber reinforced aluminum matrix composites

    SciTech Connect

    Harris, S.J.; Cai, H.W.; Zhang, G.D.; Wu, R.J.

    1993-12-31

    Thermal residual stresses in the matrix alloy of both SiC particulate 2124 aluminum alloy and Saffil ({delta}-Al{sub 2}O{sub 3}) short fiber Al-3.4%Cu composites in different heat treatment conditions were measured using a conventional X-ray diffractometer. A multi-exposure technique (sin{sup 2} {psi} method) was employed. Under all the heat-treated conditions, i.e. furnace cooled, quenched and aged, compressive residual stresses were detected in the surface regions of both composites. These measured stresses are the resultant of the micro and macro-stresses present in the composites. During aging the stress relaxed slowly at ambient and more rapidly at elevated temperatures (180{degree}C). In the Saffil short fiber composite the surface stress in the fiber plane was much reduced when compared with that in a perpendicular plane, when both samples were in the as-quenched condition. The pattern of stress relaxation is explained in part in terms of the precipitation reactions which take place in the two alloys during aging.

  13. Residual Strain Measurement on the Production-Grade Class IV Flextensional Transducer Shell

    DTIC Science & Technology

    1993-04-01

    Residual Strain Measurement on the Production-Grade Class IV Flextensional Transducer Shell J. D. Maltby Acc.,cesiO N &n For NT IS C R.A&I Dr•k: i/, ._ JL...IV flextensional transducer shell produced by Brunswick Defense. RESULTS Residual stresses deduced from the strain measurements indicate that they are...shaped shells used in one particular Class IV flextensional transducer are filament wound from fiberglass/epoxy by Brunswick Defense, Lincoln, NE

  14. Residual stress evaluation and fatigue life prediction in the welded joint by x-ray diffraction

    NASA Astrophysics Data System (ADS)

    Yoo, Keun Bong; Hwang, Kwon Tae; Chang, Jung Chel; Kim, Jae Hoon

    2009-07-01

    In the fossil power plant, the reliability of the components which consist of the many welded parts depends on the quality of welding. The residual stress is occurred by the heat flux of high temperature during weld process. This decreases the mechanical properties as the strength of fatigue and fracture. The residual stress of the welded part in the recently constructed power plants has been the cause of a variety of accidents. The objective of this study is measurement of the residual stress and the full width at half maximum intensity (FWHM) by X-ray diffraction method and to estimate the feasibility of this application for fatigue life assessment of the high-temperature pipeline. The materials used for the study is P92 steel for the use of high temperature pipe on super critical condition. The test results were analyzed by the distributed characteristics of residual stresses and FWHM in x-ray diffraction intensity curve. Also, X-ray diffraction tests using specimens simulated low cycle fatigue damage were performed in order to analyze fatigue properties when fatigue damage conditions become various stages. As a result of X-ray diffraction tests for specimens simulated fatigue damages, we conformed that the ratio of the FWHM due to fatigue damage has linear relationship with fatigue life ratio algebraically. From this relationship, it was suggested that direct expectation of the life consumption rate was feasible.

  15. Cold pulse and rotation reversals with turbulence spreading and residual stress

    SciTech Connect

    Hariri, F.; Naulin, V.; Juul Rasmussen, J.; Xu, G. S.; Yan, N.

    2016-05-15

    Transport modeling based on inclusion of turbulence spreading and residual stresses shows internal rotation reversals and polarity reversal of cold pulses, with a clear indication of nonlocal transport effects due to fast spreading in the turbulence intensity field. The effects of turbulence spreading and residual stress are calculated from the gradient of the turbulence intensity. In the model presented in this paper, the flux is carried by the turbulence intensity field, which in itself is subject to radial transport effects. The pulse polarity inversion and the rotation profile reversal positions are close to the radial location of the stable/unstable transition. Both effects have no direct explanation within the framework of classical transport modeling, where the fluxes are related directly to the linear growth rates, the turbulence intensity profile is not considered and the corresponding residual stress is absent. Our simulations are in qualitative agreement with measurements from ohmically heated plasmas. Rotation reversal at a finite radius is found in situations not displaying saturated confinement, which we identify as situations where the plasma is nearly everywhere unstable. As an additional and new effect, the model predicts a perturbation of the velocity profile following a cold pulse from the edge. This allows direct experimental confirmation of both the existence of residual stress caused by turbulence intensity profiles and fundamental ideas of transport modeling presented here.

  16. Texture Evolution and Residual Stress Relaxation in a Cold-Rolled Al-Mg-Si-Cu Alloy Using Vibratory Stress Relief Technique

    NASA Astrophysics Data System (ADS)

    Wang, Jia-Siang; Hsieh, Chih-Chun; Lin, Chi-Ming; Kuo, Che-Wei; Wu, Weite

    2013-02-01

    Over the last half century, vibratory stress relief (VSR) has come to be recognized as a technique with several unique benefits, and it has found applications in various industries. However, the mechanisms involved remain unclear, and the textures corresponding to residual stress relaxation were rarely reported in the existing literature. The purpose of this study is to discuss the texture evolution and residual stress relaxation in a cold-rolled Al-Mg-Si-Cu alloy using VSR technique. All the residual stress measurements were performed using a standard X-ray diffraction (XRD) technique. Measurement of texture was performed on the specimen surface using conventional pole figure (PF) as well as orientation distribution functions (ODFs) methods. Results indicate that the VSR technique can be applied to weaken the α-fiber and cause the residual stress of the rolled samples to gradually approach uniformity in XRD analysis. The best relaxation of the compressive residual stress reaches about 52.6 pct, but relaxation of the tensile residual stress is less than 10 pct. After the VSR process for 20 minutes, the texture intensities of PFs (200) and (220) as compared to those in nonvibration are nearly homogeneously distributed. Furthermore, the texture of (111) PF perpendicular to normal direction (ND), which is affected by vibratory force parallel to ND, almost disappears.

  17. Method for improve x-ray diffraction determinations of residual stress in nickel-base alloys

    DOEpatents

    Berman, Robert M.; Cohen, Isadore

    1990-01-01

    A process for improving the technique of measuring residual stress by x-ray diffraction in pieces of nickel-base alloys which comprises covering part of a predetermined area of the surface of a nickel-base alloy with a dispersion, exposing the covered and uncovered portions of the surface of the alloy to x-rays by way of an x-ray diffractometry apparatus, making x-ray diffraction determinations of the exposed surface, and measuring the residual stress in the alloy based on these determinations. The dispersion is opaque to x-rays and serves a dual purpose since it masks off unsatisfactory signals such that only a small portion of the surface is measured, and it supplies an internal standard by providing diffractogram peaks comparable to the peaks of the nickel alloy so that the alloy peaks can be very accurately located regardless of any sources of error external to the sample.

  18. Method for improving x-ray diffraction determinations of residual stress in nickel-base alloys

    DOEpatents

    Berman, R.M.; Cohen, I.

    1988-04-26

    A process for improving the technique of measuring residual stress by x-ray diffraction in pieces of nickel-base alloys is discussed. Part of a predetermined area of the surface of a nickel-base alloy is covered with a dispersion. This exposes the covered and uncovered portions of the surface of the alloy to x-rays by way of an x-ray diffractometry apparatus, making x-ray diffraction determinations of the exposed surface, and measuring the residual stress in the alloy based on these determinations. The dispersion is opaque to x-rays and serves a dual purpose, since it masks off unsatisfactory signals such that only a small portion of the surface is measured, and it supplies an internal standard by providing diffractogram peaks comparable to the peaks of the nickel alloy so that the alloy peaks can be very accurately located regardless of any sources of error external to the sample. 2 figs.

  19. Ultrasonic evaluation of residual stresses in flat glass tempering by an original double interferometric detection.

    PubMed

    Devos, D; Duquennoy, M; Roméro, E; Jenot, F; Lochegnies, D; Ouaftouh, M; Ourak, M

    2006-12-22

    In industrial thermal tempering of glass, the knowledge of the homogeneity of compressive residual stress field on the glass product is fundamental to guarantee the quality of the tempered glass product. In this paper, we use the acoustoelasticity phenomenon in order to estimate the residual stress distribution by using acoustic surface wave. We present an experimental setup based on a double interferometric detection in which an aspheric lens is associated with a beam splitter and a YAG laser whose power is 100 mW. This relative high power enables us to carry out measurements on surface flat glass although optical reflection coefficient is typically weak (< 10%). Using these two points of detection, the evolution of relative surface wave velocity is obtained with a good accuracy. At last, a comparison between the numerical modeling and experimental results shows the potentiality of an ultrasonic method to estimate stress distribution in flat glass tempering.

  20. Local residual stress monitoring of aluminum nitride MEMS using UV micro-Raman spectroscopy

    SciTech Connect

    Choi, Sukwon; Griffin, Benjamin A.

    2016-01-06

    Localized stress variation in aluminum nitride (AlN) sputtered on patterned metallization has been monitored through the use of UV micro-Raman spectroscopy. This technique utilizing 325 nm laser excitation allows detection of the AlN E2(high) phonon mode in the presence of metal electrodes beneath the AlN layer with a high spatial resolution of less than 400 nm. The AlN film stress shifted 400 MPa from regions where AlN was deposited over a bottom metal electrode versus silicon dioxide. Thus, across wafer stress variations were also investigated showing that wafer level stress metrology, for example using wafer curvature measurements, introduces large uncertainties for predicting the impact of AlN residual stress on the device performance.

  1. Local residual stress monitoring of aluminum nitride MEMS using UV micro-Raman spectroscopy

    DOE PAGES

    Choi, Sukwon; Griffin, Benjamin A.

    2016-01-06

    Localized stress variation in aluminum nitride (AlN) sputtered on patterned metallization has been monitored through the use of UV micro-Raman spectroscopy. This technique utilizing 325 nm laser excitation allows detection of the AlN E2(high) phonon mode in the presence of metal electrodes beneath the AlN layer with a high spatial resolution of less than 400 nm. The AlN film stress shifted 400 MPa from regions where AlN was deposited over a bottom metal electrode versus silicon dioxide. Thus, across wafer stress variations were also investigated showing that wafer level stress metrology, for example using wafer curvature measurements, introduces large uncertaintiesmore » for predicting the impact of AlN residual stress on the device performance.« less

  2. Numerical Simulation and Experimental Investigation of Residual Stresses in the Circumferential Butt GTAW of Incoloy 800H Pipes

    NASA Astrophysics Data System (ADS)

    Purmohamad, H.; Kermanpur, A.; Shamanian, M.

    2010-02-01

    The residual stresses developed during the circumferential butt gas tungsten arc welding (GTAW) process of Incoloy 800H pipes were simulated using the finite element method. A decoupled thermostructural model was developed in three dimensions. The element birth and death technique was used for the addition of filler material in the weld pool. The Goldak double ellipsoidal model was used to simulate the distribution of arc heat during welding. The plastic behavior of the material was described by Von Mises yield function and the bilinear kinematics hardening was assumed. To validate the thermostructural model, both temperature and residual stress distributions within the pipes were measured using thermocouples and strain gages, respectively. Good agreements were found between the experimental and simulation results. The model was then used to predict distribution of residual stresses during the GTAW of Incoloy 800H pipes and to study effects of process parameters on the residual stresses.

  3. Experimental residual stress evaluation of hydraulic expansion transitions in Alloy 690 steam generator tubing

    SciTech Connect

    McGregor, R.; Doherty, P.; Hornbach, D.; Abdelsalam, U.

    1995-12-31

    Nuclear Steam Generator (SG) service reliability and longevity have been seriously affected worldwide by corrosion at the tube-to-tubesheet joint expansion. Current SG designs for new facilities and replacement projects enhance corrosion resistance through the use of advanced tubing materials and improved joint design and fabrication techniques. Here, transition zones of hydraulic expansions have undergone detailed experimental evaluation to define residual stress and cold-work distribution on and below the secondary-side surface. Using X-ray diffraction techniques, with supporting finite element analysis, variations are compared in tubing metallurgical condition, tube/pitch geometry, expansion pressure, and tube-to-hole clearance. Initial measurements to characterize the unexpanded tube reveal compressive stresses associated with a thin work-hardened layer on the outer surface of the tube. The gradient of cold-work was measured as 3% to 0% within .001 inch of the surface. The levels and character of residual stresses following hydraulic expansion are primarily dependent on this work-hardened surface layer and initial stress state that is unique to each tube fabrication process. Tensile stresses following expansion are less than 25% of the local yield stress and are found on the transition in a narrow circumferential band at the immediate tube surface (< .0002 inch/0.005 mm depth). The measurements otherwise indicate a predominance of compressive stresses on and below the secondary-side surface of the transition zone. Excellent resistance to SWSCC initiation is offered by the low levels of tensile stress and cold-work. Propagation of any possible cracking would be deterred by the compressive stress field that surrounds this small volume of tensile material.

  4. The response of solids to elastic/plastic indentation. I. Stresses and residual stresses

    SciTech Connect

    Chiang, S. S.; Marshall, D. B.; Evans, A. G.

    1982-01-01

    We present a new approach for analyzing indentation plasticity and for determining indentation stress fields. The analysis permits relations to be established between material properties (notably hardness, yield strength, and elastic modulus) and the dimensions of the indentation and plastic zone. The predictions are demonstrated to correlate with observations performed on a wide range of materials. The indentation stress fields are computed along trajectories pertinent to three dominant indentation crack systems: radial, median, and lateral cracks. Lastly, the peak load and residual tensile stresses are shown to be consistent with observed trends in indentation fracture.

  5. Angular distortion and through-thickness residual stress distribution in the friction-stir processed 6061-T6 aluminum alloy

    SciTech Connect

    Woo, Wan Chuck; Choo, Hahn; Brown, D. W.; Feng, Zhili; Liaw, Peter K; Hubbard, Camden R

    2006-01-01

    Residual stresses were measured through the thickness of friction-stir processed (FSP) 6061-T6 aluminum-alloy plates using neutron diffraction. Two different specimens were prepared to study the relationship between residual stress distributions through the thickness of the plate and angular distortion: (Case 1) a plate processed with both stirring pin and tool shoulder, i.e., a typical FSP plate subjected to both plastic deformation and frictional heat, and (Case 2) a plate processed only with the tool shoulder, i.e., subjected mainly to the frictional heating. The measured residual stress profiles show relatively small through-thickness residual stress variations in Case 1, while there is a significant through-thickness residual stress variations in Case 2. The main cause of the geometric angular distortion could be related to the non-uniform distribution of the frictional heat generated by the tool shoulder leading to the asymmetric distributions of the residual stress through the thickness of the FSP plate.

  6. RESIDUAL LIMB VOLUME CHANGE: SYSTEMATIC REVIEW OF MEASUREMENT AND MANAGEMENT

    PubMed Central

    Sanders, JE; Fatone, S

    2014-01-01

    Management of residual limb volume affects decisions regarding timing of fit of the first prosthesis, when a new prosthetic socket is needed, design of a prosthetic socket, and prescription of accommodation strategies for daily volume fluctuations. The purpose of this systematic review was to assess what is known about measurement and management of residual limb volume change in persons with lower-limb amputation. Publications that met inclusion criteria were grouped into three categories: (I) descriptions of residual limb volume measurement techniques; (II) studies on people with lower-limb amputation investigating the effect of residual limb volume change on clinical care; and (III) studies of residual limb volume management techniques or descriptions of techniques for accommodating or controlling residual limb volume. The review showed that many techniques for the measurement of residual limb volume have been described but clinical use is limited largely because current techniques lack adequate resolution and in-socket measurement capability. Overall, there is limited evidence regarding the management of residual limb volume, and the evidence available focuses primarily on adults with trans-tibial amputation in the early post-operative phase. While we can draw some insights from the available research about residual limb volume measurement and management, further research is required. PMID:22068373

  7. Residual surface stresses in laminated cross-ply fiber-epoxy composite materials

    NASA Astrophysics Data System (ADS)

    Gascoigne, Harold E.

    Residual (curing) stresses in cross-ply laminated panels are related to the strains released when individual plies are separated. Released strains are determined using high-sensitivity moire interferometry. Elastic orthotropic stress-strain relations are used to calculate residual stresses. Residual strains and stresses are determined on the lateral surface and at the free-edge of a cross-ply panel. The circumferential and radial residual stresses near the outer surface of a thick-walled cross-ply cylinder are determined.

  8. Relaxation of bending stresses and the reversibility of residual stresses in amorphous soft magnetic alloys

    SciTech Connect

    Kekalo, I. B.; Mogil’nikov, P. S.

    2015-06-15

    The reversibility of residual bending stresses is revealed in ribbon samples of cobalt- and iron-based amorphous alloys Co{sub 69}Fe{sub 3.7}Cr{sub 3.8}Si{sub 12.5}B{sub 11} and Fe{sub 57}Co{sub 31}Si{sub 2.9}B{sub 9.1}: the ribbons that are free of applied stresses and bent under the action of residual stresses become completely or incompletely straight upon annealing at the initial temperatures. The influence of annealing on the relaxation of bending stresses is studied. Preliminary annealing is found to sharply decrease the relaxation rate of bending stresses, and the initial stage of fast relaxation of these stresses is absent. Complete straightening of preliminarily annealed ribbons is shown to occur at significantly higher temperatures than that of the initial ribbons. Incomplete straightening of the ribbons is explained by the fact that bending stresses relaxation at high annealing temperatures proceeds due to both reversible anelastic deformation and viscous flow, which is a fully irreversible process. Incomplete reversibility is also caused by irreversible processes, such as the release of excess free volume and clustering (detected by small-angle X-ray scattering). The revealed differences in the relaxation processes that occur in the cobalt- and iron-based amorphous alloys are discussed in terms of different atomic diffusion mobilities in these alloys.

  9. Operator Manual for X-ray Residual Stress Mapping

    SciTech Connect

    Wright, M.C.

    2003-07-30

    This document is intended to serve as a operator manual for remote control of the TEC x-ray diffraction system. It is assumed that the reader is familiar with the operation of the SaraTEC{trademark} 1630 Acquisition Manager software for the TEC 1630 X-Ray Diffraction System. This manual describes the operation of the new TEC Remote Serial Control Module (RCSM) that runs on the TEC computer and Run-the-System that runs on the motion control computer. The basic goal is to add enough control of the TEC system to enable stress mapping. In stress mapping, the specimen is positioned using our X-Y-Z-Phi translation system and data is collected using the TEC system. The process is then repeated for the next position using a table of preset positions. X-Y-Z-Phi axis management is handled by ''Run-the-System'', the LabVIEW program originally developed for the Neutron Residual Stress Mapping Facility, running on a separate computer from the one that controls the TEC. Run-the-System also manages all remote start, stop, and configuration commands that are sent to the TEC system. The two computers communicate over an RS-232 serial line.

  10. Using a Coupled Thermal/Material Flow Model to Predict Residual Stress in Friction Stir Processed AlMg9Si

    NASA Astrophysics Data System (ADS)

    Hamilton, C.; Węglowski, M. St.; Dymek, S.; Sedek, P.

    2015-03-01

    A coupled thermal/material flow model of friction stir processing is developed for friction stir processing of an as-cast AlSi9Mg aluminum alloy. By capturing material flow during processing, an asymmetric temperature distribution is generated with higher processing temperatures on the advancing side than on the retreating side. The temperature distribution from the coupled model is then incorporated into a thermomechanical model to predict the residual stress state after processing. These numerical results are compared with the residual stresses experimentally measured by the trepanation method. Experimental results show that the tensile residual stresses are higher on the advancing side than on the retreating side. The simulation successfully captures the asymmetric behavior of the residual stress profile, and the predicted maximum residual stress values show relatively good agreement with the experimental values. The simulated profile, however, is narrower than the experimental profile, yielding a smaller region of tensile residual stresses around the process zone than experimentally observed.

  11. Local surface skimming longitudinal wave velocity and residual stress mapping.

    PubMed

    Sathish, Shamachary; Martin, Richard W; Moran, Thomas J

    2004-01-01

    Local variation in surface skimming longitudinal wave (SSLW) velocity has been measured using a scanning acoustic microscope. A very narrow width electrical impulse has been used to excite the transducer of the acoustic lens. This permits the separation of the SSLW signal from the direct reflected signal in the time domain. A simple method of measuring the time delay between the directly reflected signal and the SSLW signal at two defocuses has been utilized for the local measurement of SSLW velocity. The variation in the SSLW velocity measured over an area of the sample is scaled and presented as an image. The method has been implemented to image the variation of the SSLW velocity around a crack tip in a sample of Ti-6Al-4V. Since the SSLW velocity is known to change linearly with the stress, the SSLW velocity image is considered as a representation of the image of stress around the crack tip. Local stress variation in the same region of the crack tip is directly measured using x-ray diffraction. The SSLW velocity image is compared with the x-ray diffraction stress image. The contrast in the two images, spatial resolution, and the penetration depth into the sample of acoustic waves and x rays are discussed.

  12. Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Newman, John A.; Smith, Stephen W.; Seshadri, Banavara R.; James, Mark A.; Brazill, Richard L.; Schultz, Robert W.; Donald, J. Keith; Blair, Amy

    2015-01-01

    An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

  13. Solder Paste and Residue Measurement System

    DTIC Science & Technology

    1999-12-21

    flouridic conversion of fee S„0 oxide caused the solder paste material to shear fein more readily under high stress. This shear thinning phenom...enon was tracked by an increase in the thixotropic index. In FIG. 19, Tau-2 was tracking this flouridic conversion. Once fee O—S„—F formed on fee

  14. Laboratory experiments, high angular-resolution EBSD, and micromechanical modelling reveal residual stresses and their distribution in deformed olivine

    NASA Astrophysics Data System (ADS)

    Hansen, Lars; Wallis, David; Kempton, Imogen; Lebensohn, Ricardo; Wilkinson, Angus

    2017-04-01

    of stress-dip tests. Third, we implement an elasto-visco-plastic spectral micromechanical model to predict the full stress field in a deforming olivine aggregate. An EBSD map of an experimentally deformed aggregate was used as the input microstructure, and predicted stresses are compared to those measured by HR-EBSD. Observations from the three different methods confirm that both stress heterogeneities during deformation and residual stresses remaining after external unloading can be on the same order as the applied stress during deformation. As such, these results provide important new constraints to be incorporated in future geodynamic simulations. Furthermore, cross validation of HR-EBSD with stress-dip tests and numerical simulations suggests HR-EBSD is a viable tool for assessing residual stresses in previously deformed rocks. We will attempt to tune the numerical simulations to best predict observed residual stresses such that simulations can be used to interpret stress distributions observed in natural rocks deformed in ancient tectonic events.

  15. Comparison of Residual Stresses in Inconel 718 Simple Parts Made by Electron Beam Melting and Direct Laser Metal Sintering

    NASA Astrophysics Data System (ADS)

    Sochalski-Kolbus, L. M.; Payzant, E. A.; Cornwell, P. A.; Watkins, T. R.; Babu, S. S.; Dehoff, R. R.; Lorenz, M.; Ovchinnikova, O.; Duty, C.

    2015-03-01

    Residual stress profiles were mapped using neutron diffraction in two simple prism builds of Inconel 718: one fabricated with electron beam melting (EBM) and the other with direct laser metal sintering. Spatially indexed stress-free cubes were obtained by electrical discharge machining (EDM) equivalent prisms of similar shape. The (311) interplanar spacings from the EDM sectioned sample were compared to the interplanar spacings calculated to fulfill stress and moment balance. We have shown that applying stress and moment balance is a necessary supplement to the measurements for the stress-free cubes with respect to accurate stress calculations in additively manufactured components. In addition, our work has shown that residual stresses in electron beam melted parts are much smaller than that of direct laser metal sintered parts most likely due to the powder preheating step in the EBM process.

  16. Blocks and residual stresses in sapphire rods of different crystallographic orientations grown by the Stepanov method

    SciTech Connect

    Krymov, V. M. Nosov, Yu. G.; Bakholdin, S. I.; Maslov, V. N.; Shul’pina, I. L.

    2015-05-15

    The formation of blocks in shaped sapphire rods of two crystallographic orientations has been investigated. It is shown that, when growth occurs in the direction of the optical c axis, blocks are formed with a higher probability than in the case of growth in the a direction. A model of formation of blocks in rods of different orientations is proposed. The distribution of residual stresses over sapphire rod cross sections is measured by conoscopy. It is found that stresses increase from the middle of a rod to its periphery and reach 20 MPa.

  17. Residual Stress Analysis of Boronized AISI 1018 Steel

    SciTech Connect

    Payne,J.; Petrova, R.; White, H.; Chauhan, A.; Bai, J.

    2008-01-01

    AISI 1018 steel substrates were powder-pack, diffusion boronized at 850 C for 4 h, followed by air quenching. Optical microscopy in conjunction with color etching was used to obtain the average penetration depth of the iron monoboride layer (9 {mu}m) and the iron diboride layer (57 {mu}m). X-ray diffraction by synchrotron radiation, conducted at the National Synchrotron Light Source in Brookhaven National Laboratory, confirmed the presence of iron monoboride and iron diboride in the boronized plain steel substrates. The sin2 {psi} technique was employed to calculate the residual stress found in the iron monoboride layer (-237 MPa) and in the substrate layer (-150 MPa) that is intertwined with the needle-like, iron diboride penetration.

  18. Finite element residual stress analysis of induction heating bended ferritic steel piping

    SciTech Connect

    Kima, Jong Sung; Kim, Kyoung-Soo; Oh, Young-Jin; Chang, Hyung-Young; Park, Heung-Bae

    2014-10-06

    Recently, there is a trend to apply the piping bended by induction heating process to nuclear power plants. Residual stress can be generated due to thermo-mechanical mechanism during the induction heating bending process. It is well-known that the residual stress has important effect on crack initiation and growth. The previous studies have focused on the thickness variation. In part, some studies were performed for residual stress evaluation of the austenitic stainless steel piping bended by induction heating. It is difficult to find the residual stresses of the ferritic steel piping bended by the induction heating. The study assessed the residual stresses of induction heating bended ferriticsteel piping via finite element analysis. As a result, it was identified that high residual stresses are generated on local outersurface region of the induction heating bended ferritic piping.

  19. Finite element residual stress analysis of induction heating bended ferritic steel piping

    NASA Astrophysics Data System (ADS)

    Kima, Jong Sung; Kim, Kyoung-Soo; Oh, Young-Jin; Chang, Hyung-Young; Park, Heung-Bae

    2014-10-01

    Recently, there is a trend to apply the piping bended by induction heating process to nuclear power plants. Residual stress can be generated due to thermo-mechanical mechanism during the induction heating bending process. It is well-known that the residual stress has important effect on crack initiation and growth. The previous studies have focused on the thickness variation. In part, some studies were performed for residual stress evaluation of the austenitic stainless steel piping bended by induction heating. It is difficult to find the residual stresses of the ferritic steel piping bended by the induction heating. The study assessed the residual stresses of induction heating bended ferriticsteel piping via finite element analysis. As a result, it was identified that high residual stresses are generated on local outersurface region of the induction heating bended ferritic piping.

  20. Effect of residual stresses induced by prestressing on rolling element fatigue life

    NASA Technical Reports Server (NTRS)

    Parker, R. J.; Zaretsky, E. V.

    1972-01-01

    A mechanical prestress cycle suitable to induce compressive stress beneath the surface of the inner race of radially loaded 207-size bearings was determined. Compressive residual stress in excess 0.69 x 10 to the 9th power N/sq m (100,000 psi), as measured by X-ray diffraction, were induced at the depth of maximum shearing stress. The prestress cycle consisted of running the bearings for 25 hours at 2750 rpm at a radial load which produced a maximum Hertz stress of 3.3 x 10 to the 9th power N/sq m (480,000 psi) at the contact of the inner race and the heaviest loaded ball. Bearings subjected to this prestress cycle and subsequently fatigue tested gave a 10 percent fatigue life greater than twice that of a group of baseline bearings.

  1. Residual Stress Development in Explosive-Bonded Bi-Metal Composite Materials

    DTIC Science & Technology

    2014-03-01

    distribution of the residual stress over the welded material, especially at the interface area. Similar and dissimilar steel plate materials possessing...explosive welding for improved mechanical and corrosion properties of bimetal composite materials is the potential for a residual stress contour to exist at...residual stress over the welded material, especially at the interface area. A range of varieties of steel plate materials, possessing different

  2. Mechanisms of Residual Stress Generation in Mechanical Surface Treatment: the Role of Cyclic Plasticity and Texture

    DTIC Science & Technology

    2015-08-24

    residual stresses were characterized by the incremental hole drilling technique. The effect of laser peening parameters on the magnitude, depth, and the...characterised by the nanoindentation technique, and the residual stresses were characterised by the incremental hole drilling technique. The effect of laser...conditions, induced residual stresses and hardness, and material state; and also by providing validation data for various predictive models that will apply

  3. Neutron diffraction residual strain measurements in nanostructured hydroxyapatite coatings for orthopaedic implants.

    PubMed

    Ahmed, R; Faisal, N H; Paradowska, A M; Fitzpatrick, M E; Khor, K A

    2011-11-01

    The failure of an orthopaedic implant can be initiated by residual strain inherent to the hydroxyapatite coating (HAC). Knowledge of the through-thickness residual strain profile in the thermally sprayed hydroxyapatite coating/substrate system is therefore important in the development of a new generation of orthopaedic implants. As the coating microstructure is complex, non-destructive characterization of residual strain, e.g. using neutron diffraction, provides a useful measure of through thickness strain profile without altering the stress field. This first detailed study using a neutron diffraction technique, non-destructively evaluates the through thickness strain measurement in nanostructured hydroxyapatite plasma sprayed coatings on a titanium alloy substrate (as-sprayed, heat treated, and heat treated then soaked in simulated body fluid (SBF)). The influence of crystallographic plane orientation on the residual strain measurement is shown to indicate texturing in the coating. This texturing is expected to influence both the biological and fracture response of HA coatings. Results are discussed in terms of the influence of heat-treatment and SBF on the residual stress profile for these biomedical coatings. The results show that the through thickness residual strain in all three coatings was different for different crystallographic planes but was on average tensile. It is also concluded that the heat-treatment and simulated body fluid exposure had a significant effect on the residual strain profile in the top layers of HAC.

  4. A review of inducing compressive residual stress - shot peening; on structural metal and welded connection

    NASA Astrophysics Data System (ADS)

    Kanchidurai, S.; Krishanan, P. A.; Baskar, K.; Saravana Raja Mohan, K.

    2017-07-01

    Shot peening treatment (SPT) is a significant mechanical method to enhance the surface of the material by inducing compressive residual stress on the layer. This study provides a review of prominent improvement in fatigue life on high strength aluminium alloy, steel and welded connection by SPT. Compressive residual stress measurement and its factors data are extracted from assorted literature, optimized peening process commented in this paper, also different types of mechanical peening methods and its effectiveness are mentioned. Fatigue life improvement is focused commented to welded structural connections. The extracted results shows significant changes in the surface layer of metals, aluminium alloy 15 - 250% of fatigue life improvement, steel plain members 6-200% of fatigue life improvement, welded connections 50-75% of fatigue life improvement and significant improvement in mechanical properties like roughness reduction, wear, hardness, tensile strength, corrosion and scuffing.

  5. Residual stress effects on fracture energies of cement-bone and cement-implant interfaces.

    PubMed

    Zor, Mehmet; Küçük, Mümin; Aksoy, Sami

    2002-04-01

    The effects of residual stresses, which are caused by the temperature difference arising after polymerisation of bone cement, on the fracture energies of cement bone and cement-implant interfaces have been examined by using both experimental and numerical works. Only fracture loads of the test specimen having interfacial cracks have been measured in the experimental stage. The values of fracture loads and temperature difference after polymerisation have been applied to finite element models of the test specimens to calculate critical J-integral values of these both interfaces in the numerical stage. In addition, fracture energies of bone and cement, have been obtained by experimentally, using three-point bending test method The results have shown that residual stresses can produce changes in the fracture energies of these bimaterial systems, especially in cement implant interface and J(Ic) values of interfaces are considerably smaller than the experimentally determined J(Ic) values of cement and bone.

  6. Extended glaze firing on ceramics for hard machining: Crack healing, residual stresses, optical and microstructural aspects.

    PubMed

    Aurélio, Iana L; Dorneles, Lucio S; May, Liliana G

    2017-02-01

    To evaluate the effect of extended and conventional (manufacturer-recommended) glaze firings on crack healing, residual stresses, optical characteristics and crystalline structure of four ceramics for hard machining. Rectangular specimens were obtained by sectioning densely sintered feldspathic (FEL), leucite- (LEU), lithium disilicate- (DIS), and zirconia-reinforced lithium silicate-based (ZLS) prefabricated ceramic blocks and divided into groups according to the applied glaze firing (n=5): conventional glaze/manufacturer-recommended (G), extended glaze (EG) and control/no heat treatment (C). Defects generated by indentation were analyzed by scanning electron microscopy before and after firing (n=1) to evaluate crack healing. Residual stresses were determined by the indentation technique. Color differences (ΔE) after firing were measured by CIEDE2000 formula, and translucency variations were quantified by contrast ratio. Stability of crystalline microstructure was analyzed by X-ray diffraction. Regardless of the material, EG had greater ability than G to heal defects, and produced compressive residual stresses, while G generated tensile stresses. Color differences produced by EG were: imperceptible for FEL and LEU ceramics; perceptible, but still clinically acceptable for DIS; clinically unacceptable for ZLS. G produced no perceptible color change. The DIS and ZLS ceramics became ≈1% more opaque after G, ≈4% and ≈15%, respectively, after EG. The crystalline phase of all the ceramics remained stable after G and EG. Extended glaze firing could be an alternative to finish feldspathic, leucite-, and lithium disilicate-based ceramic restorations, since it provides greater crack healing than the conventional glaze firing. It develops tolerable residual stresses, and produces clinically acceptable color alterations, without altering the microstructure of these materials. Copyright © 2016 The Academy of Dental Materials. Published by Elsevier Ltd. All rights

  7. Nondestructive Induced Residual Stress Assessment in Superalloy Turbine Engine Components Using Induced Positron Annihilation (IPA)

    SciTech Connect

    Rideout, C. A.; Ritchie, S. J.; Denison, A.

    2007-03-21

    Induced Positron Analysis (IPA) has demonstrated the ability to nondestructively quantify shot peening/surface treatments and relaxation effects in single crystal superalloys, steels, titanium and aluminum with a single measurement as part of a National Science Foundation SBIR program and in projects with commercial companies. IPA measurement of surface treatment effects provides a demonstrated ability to quantitatively measure initial treatment effectiveness along with the effect of operationally induced changes over the life of the treated component. Use of IPA to nondestructively quantify surface and subsurface residual stresses in turbine engine materials and components will lead to improvements in current engineering designs and maintenance procedures.

  8. Directionality of residual stress evaluated by instrumented indentation testing using wedge indenter

    NASA Astrophysics Data System (ADS)

    Ahn, Hee-Jun; Kim, Jong-hyoung; Xu, Huiwen; Lee, Junsang; Kim, Ju-Young; Kim, Young-Cheon; Kwon, Dongil

    2017-05-01

    In instrumented indentation testing (IIT), residual stress can be evaluated by shift in indentation load-depth curves for stress-free and stressed states. Although the average surface residual stress is able to be evaluated with Vickers indenter, in order to know stress directionality, another indentation tests with two-fold symmetric indenter, for example, Knoop indenter, are needed. As some necessities for evaluating nonequibiaxial residual stress within small indent area, we suggest a novel way to evaluate directionality of residual stress, p, using wedge indenter characterized by two parameters, edge length and inclined angle. We develop wedge-indentation-mechanics model based on predetermined conversion factors which are determined by IITs for various uniaxial stressed states combining with finite element analysis simulations. By utilizing the developed model, directionality of residual stress is evaluated through two serial wedge IITs with respect to principal directions. We find good agreements between applied residual stress and residual stress evaluated by the developed model for biaxial tensile stress states.

  9. Development of ultrasonic tomography for residual stress mapping. Final report

    SciTech Connect

    Boland, A.J.; Davis, T.J.; Doctor, S.R.; Harrington, T.P.; Hildebrand, B.P.; Lemon, D.K.; Posakony, G.J.; Skorpik, J.R.

    1980-05-01

    The volumetric stress distribution in nuclear reactor piping and pressure vessels is becoming an increasingly important parameter in nondestructive evaluation. This report describes research and development of instrumentation leading toward a means of measuring subsurface stress distributions in metals. Based on the principles of Computerized Tomography (CT), an ultrasonic tomographic instrument system has been developed. The microprocessor-based system uses an ultrasonic linear array to acquire time-of-flight data to an accuracy of 0.5 to 1.0 ns. The data is processed using a modified ART (Algebraic Reconstruction Technique) program. A two-dimensional map of the velocity distribution is displayed on a monitor. The velocity distribution is interpreted or calibrated in terms of stress through the acousto-elastic coefficients.

  10. Evolution of residual stress, free volume, and hardness in the laser shock peened Ti-based metallic glass

    SciTech Connect

    Wang, Liang; Wang, Lu; Nie, Zhihua; Ren, Yang; Xue, Yunfei; Zhu, Ronghua; Zhang, Haifeng; Fu, Huameng

    2016-12-05

    Laser shock peening (LSP) with different cycles was performed on the Ti-based bulk metallic glasses (BMGs). The sub-surface residual stress of the LSPed specimens was measured by high-energy X-ray diffraction (HEXRD) and the near-surface residual stress was measured by scanning electron microscope/focused ion beam (SEM/FIB) instrument. The sub-surface residual stress in the LSP impact direction (about-170MPa) is much lower than that perpendicular to the impact direction (about -350 MPa), exhibiting anisotropy. The depth of the compressive stress zone increases from 400 mu m to 500 mu m with increasing LSP cycles. The highest near-surface residual stress is about -750 MPa. LSP caused the free volume to increase and the maximum increase appeared after the first LSP process. Compared with the hardness (567 +/- 7 HV) of the as-cast BMG, the hardness (590 +/- 9 HV) on the shocked surface shows a hardening effect due to the hardening mechanism of compressive residual stress; and the hardness (420 +/- 9 HV) on the longitudinal section shows a softening effect due to the softening mechanism of free volume.

  11. Stress Free Temperature Testing and Residual Stress Calculations on Out-of-Autoclave Composites

    NASA Technical Reports Server (NTRS)

    Cox, Sarah; Tate, LaNetra C.; Danley, Susan; Sampson, Jeff; Taylor, Brian; Miller, Sandi

    2012-01-01

    Future launch vehicles will require the incorporation large composite parts that will make up primary and secondary components of the vehicle. NASA has explored the feasibility of manufacturing these large components using Out-of-Autoclave impregnated carbon fiber composite systems through many composites development projects. Most recently, the Composites for Exploration Project has been looking at the development of a 10 meter diameter fairing structure, similar in size to what will be required for a heavy launch vehicle. The development of new material systems requires the investigation of the material properties and the stress in the parts. Residual stress is an important factor to incorporate when modeling the stresses that a part is undergoing. Testing was performed to verify the stress free temperature with two-ply asymmetric panels. A comparison was done between three newly developed out of autoclave IM7 /Bismalieimide (BMI) systems. This paper presents the testing results and the analysis performed to determine the residual stress of the materials.

  12. Laser quench hardening of steel: Effects of superimposed elastic pre-stress on the hardness and residual stress distribution

    NASA Astrophysics Data System (ADS)

    Meserve, Justin

    Cold drawn AISI 4140 beams were LASER surface hardened with a 2 kW CO2 LASER. Specimens were treated in the free state and while restrained in a bending fixture inducing surface tensile stresses of 94 and 230 MPa. Knoop hardness indentation was used to evaluate the through thickness hardness distribution, and a layer removal methodology was used to evaluate the residual stress distribution. Results showed the maximum surface hardness attained was not affected by pre-stress during hardening, and ranged from 513 to 676 kg/mm2. The depth of effective hardening varied at different magnitudes of pre-stress, but did not vary proportionately to the pre-stress. The surface residual stress, coinciding with the maximum compressive residual stress, increased as pre-stress was increased, from 1040 MPa for the nominally treated specimens to 1270 MPa for specimens pre-stressed to 230 MPa. The maximum tensile residual stress observed in the specimens decreased from 1060 MPa in the nominally treated specimens to 760 MPa for specimens pre-stressed to 230 MPa. Similarly, thickness of the compressive residual stress region increased and the depth at which maximum tensile residual stress occurred increased as the pre-stress during treatment was increased Overall, application of tensile elastic pre-stress during LASER hardening is beneficial to the development of compressive residual stress in AISI 4140, with minimal impact to the hardness attained from the treatment. The newly developed approach for LASER hardening may support efforts to increase both the wear and fatigue resistance of parts made from hardenable steels.

  13. The effect of cutting speed on residual stresses when orthogonal cutting TC4

    NASA Astrophysics Data System (ADS)

    Liu, Chaofeng; Wang, Zengqiang; Zhang, Guang; Liu, Lei

    2015-09-01

    As one of the most important parameters in mental cutting, cutting speed has a significant influence on residual stress. Finite element method and experiment method are used to study the relationship between cutting speed and residual stress when orthogonal cutting TC4 titanium alloy. The result of simulation and experiment shows that: when the cutting speed is low, the residual stress in axial direction is compressive stress and gradually converts to tensile stress with the increase of cutting speed, but it will convert to compressive stress again if the cutting speed continues to increase; the residual stress in tangential direction is constant to compressive stress and it will decrease with the increase of cutting speed.

  14. Residual stress effects on the impact resistance and strength of fiber composites

    NASA Technical Reports Server (NTRS)

    Chamis, C. C.

    1973-01-01

    Equations have been derived to predict degradation effects of microresidual stresses on impact resistance of unidirectional fiber composites. Equations also predict lamination residual stresses in multilayered angle ply composites.

  15. An accurate method for determining residual stresses with magnetic non-destructive techniques in welded ferromagnetic steels

    NASA Astrophysics Data System (ADS)

    Vourna, P.

    2016-03-01

    The scope of the present research work was to investigate the proper selection criteria for developing a suitable methodology for the accurate determination of residual stresses existing in welded parts. Magnetic non-destructive testing took place by the use of two magnetic non-destructive techniques: by the measurement of the magnetic Barkhausen noise and by the evaluation of the magnetic hysteresis loop parameters. The spatial distribution of residual stresses in welded metal parts by both non-destructive magnetic methods and two diffraction methods was determined. The conduction of magnetic measurements required an initial calibration of ferromagnetic steels. Based on the examined volume of the sample, all methods used were divided into two large categories: the first one was related to the determination of surface residual stress, whereas the second one was related to bulk residual stress determination. The first category included the magnetic Barkhausen noise and the X-ray diffraction measurements, while the second one included the magnetic permeability and the neutron diffraction data. The residual stresses determined by the magnetic techniques were in a good agreement with the diffraction ones.

  16. Stress, anticipatory stress, and psychologic measures related to sleep bruxism.

    PubMed

    Pierce, C J; Chrisman, K; Bennett, M E; Close, J M

    1995-01-01

    This study examined (1) the relationships between electromyographic-measured nocturnal bruxism, self-reported stress, and several personality variables, and (2) the relationship between belief in a stress-bruxism relationship and self-reported stress. One hundred adult bruxers completed a battery of personality questionnaires, indicated whether they believed in a stress-bruxism relationship, presented for a dental examination, and had dental impressions taken. Subsequently, electromyographic measurements of bruxing frequency and duration were recorded for fifteen consecutive nights. Prior to each night's measurements, subjects indicated their levels of stress for the immediately preceding 24 hours. No overall relationship was established between electromyographic measures and the personality variables nor between electromyographic measures and self-reported stress. Correlations between electromyographic measures and self-reported stress were statistically significant for eight individual subjects. Further, subjects with high levels of stress reported more anxiety, irritability, and depression, and less denial. Subjects who believed in a stress-bruxism relationship reported greater stress.

  17. Process-induced residual stresses and dimensional distortions in advanced laminated composites

    NASA Astrophysics Data System (ADS)

    Niu, Xiaokai

    Process induced residual stresses can degrade the performance of composite structures by consuming a significant portion of the strength in certain plies. Cracking due to overload of these plies can then lead to degradation by environmental effects. A technique called cure referencing method (CRM) has been developed for determining the residual stresses in flat laminated composites. In this technique a diffraction grating used for moire interferometry is transferred onto a composite laminate from a master autoclave tool during the curing process. This transfer takes place at the cure temperature where the matrix solidifies from the liquid state. After cure and upon cooling, the deformation of the composite is recorded with moire interferometry using the tool grating as the reference. The deformation of the composite is then a function of the thermal contraction due to the temperature difference from the cure temperature to room temperature and the deformation caused by chemical shrinkage. These measurements are first conducted on a unidirectional lamina. Using a specially designed oven, the thermal contraction component of the deformation is separated from the overall deformation. For flat multidirectional symmetrical laminates, the residual stresses in each layer and the in-plane dimensional distortions of the laminate are then calculated from the unidirectional information, constitutive equations, equilibrium equations, and compatibility conditions. Several assumptions, which are similar to those used in laminate theory, are also adopted. An independent method called shadow moire is used to validate CRM. The shadow moire method is used to measure the curvature of asymmetrical laminates while the lamination theory is used to calculate the curvature from lamina strain information measured with CRM. Good agreement validates the CRM. In addition, process induced strains on multi-directional composites were measured with the CRM. The validation of CRM and the

  18. Hysteresis loop as the indicator of residual stress in drawn wires

    NASA Astrophysics Data System (ADS)

    Suliga, Maciej; Chwastek, Krzysztof; Pawlik, Piotr

    2014-04-01

    The paper investigates the possibility of using the magnetic method for non-destructive determination of residual stress in drawn wires. The change in residual stress for different processing speeds is reflected in the shape of hysteresis loop. A simple model for stress-dependent hysteresis, based on the concept of the effective field, is proposed. The effective field includes an additional term related to stress, in accordance with previous Jiles' and Sablik's results. The presented description may be useful for technologists seeking a simple tool for predicting residual stress.

  19. Application of neutron diffraction to measure residual strains in high temperature composites

    SciTech Connect

    Saigal, A. . Dept. of Mechanical Engineering); Kupperman, D.S. )

    1991-01-01

    An experimental neutron diffraction technique was used to measure residual thermal strains developed in high temperature composites during postfabrication cooling. Silicon carbide fiber-reinforced titanium aluminide (over the temperature range 20--950{degree}C) and tungsten and saphikon fiber-reinforced nickel aluminide composites (at room temperature) were investigated. As a result of thermal expansion mismatch, compressive residual strains and stresses were generated in the silicon carbide fibers during cooldown. The axial residual strains were tensile in the matrix and were lower in nickel aluminide matrix as compared to those in titanium aluminide matrix. The average transverse residual strains in the matrix were compressive. Liquid-nitrogen dipping and thermal-cycling tend to reduce the fabrication-induced residual strains in silicon carbide fiber-reinforced titanium aluminide matrix composite. However, matrix cracking can occur as a result of these processes. 10 refs., 5 figs., 2 tabs.

  20. Morphology of residually stressed tubular tissues: Beyond the elastic multiplicative decomposition

    NASA Astrophysics Data System (ADS)

    Ciarletta, P.; Destrade, M.; Gower, A. L.; Taffetani, M.

    2016-05-01

    Many interesting shapes appearing in the biological world are formed by the onset of mechanical instability. In this work we consider how the build-up of residual stress can cause a solid to buckle. In all past studies a fictitious (virtual) stress-free state was required to calculate the residual stress. In contrast, we use a model which is simple and allows the prescription of any residual stress field. We specialize the analysis to an elastic tube subject to a two-dimensional residual stress, and find that incremental wrinkles can appear on its inner or its outer face, depending on the location of the highest value of the residual hoop stress. We further validate the predictions of the incremental theory with finite element simulations, which allow us to go beyond this threshold and predict the shape, number and amplitude of the resulting creases.

  1. Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work

    NASA Astrophysics Data System (ADS)

    Clyne, T. W.; Gill, S. C.

    1996-12-01

    An overview is presented of the development of residual stresses in thermal spray coatings and their ef-fects on interfacial debonding. The main experimental techniques for measurement of residual stresse are briefly described, with particular attention given to the method of continuous curvature monitoring. Boundary conditions satisfied by all residual stress distributions are identified and expressions derived for the curvatures and stress distributions arising from a uniform misfit strain between coating and sub-strate.It is noted that stress distributions in thick coatings rarely correspond to the imposition of such a uniform misfit strain, so that recourse to numerical methods becomes essential for quantitative predic-tion of stress distributions. Relationships are presented between residual stresses and corresponding strain energy release rates during interfacial debonding. The effect on this of superimposing stresses from an externally applied load is outlined. The initiation of debonding is then considered, covering edge effects and other geometrical considerations. Finally, some specific case histories are briefly outlined to illustrate how the various theoretical concepts involved relate to industrial practice.

  2. Residual stresses in a ferritic steel welded pipe: an experimental comparison between reactor and pulsed neuron sources

    NASA Astrophysics Data System (ADS)

    Albertini, Gianni; Brugnami, D.; Bruno, Giovanni; Ceretti, M.; Cernuschi, F. M.; Edwards, Lyndon

    1997-02-01

    Residual stresses induced by welding processes can affect the integrity of structural components like tubes and pipes of thermoelectric power plants. In order to reduce or cancel these stresses, welded components are often heat treated. The residual stress field in an arc-welded 2.25Cr1Mo ferritic steel pipe was measured using neutron diffraction both before and after stress relieving heat treatment. In the first stage stresses were measured using two different kinds of neutron sources: a reactor and a pulsed one. A comparison between results obtained using G5.2 diffractometer at LLB and ENGIN equipment at ISIS will be outlined and the effectiveness of heat treatment will be shown.

  3. The relationships between residual stress relaxation and texture development in AZ31 Mg alloys via the vibratory stress relief technique

    SciTech Connect

    Wang, Jia-Siang; Hsieh, Chih-Chun; Lai, Hsuan-Han; Kuo, Che-Wei; Wu, Paxon Ti-Yuan; Wu, Weite

    2015-01-15

    A systematic study of residual stress relaxation and the texture evolution of cold-rolled AZ31 Mg alloys using the vibratory stress relief technique with a simple cantilever beam vibration system was performed using a high-resolution X-ray diffractometer and a portable X-ray residual stress analyzer. The effects of vibrational stress excitation on the surface residual stress distribution and on the texture of pole figures (0002) occurring during the vibratory stress relief were examined. Compared with the effects corresponding to the same alloy under non-vibration condition, it can be observed that the uniform surface residual stress distribution and relaxation of the compressive residual stress in the stress concentration zone were observed rather than all of the residual stresses being eliminated. Furthermore, with an increase in the vibrational aging time, the compressive residual stress, texture density, and (0002) preferred orientation increased first and then decreased. It should be underlined that the vibratory stress relief process for the vibrational aging time of more than 10 min is able to weaken the strong basal textures of AZ31 Mg alloys, which is valuable for enhancement of their formability and is responsible for an almost perfect 3D-Debye–Scherrer ring. - Highlights: • 3D-Debye ring about VSR technique is not discussed in the existing literature. • A newly developed VSR method is suitable for small or thin workpieces. • The cosα method accurately and effectively determines the residual stresses. • The VSR technique is valuable for enhancement of their formability. • The texture and preferred orientation change with the vibrational aging time.

  4. Effect of argon gas pressure on residual stress, microstructure evolution and electrical resistivity of beryllium films

    NASA Astrophysics Data System (ADS)

    Luo, Bing-Chi; Li, Kai; Zhang, Ji-Qiang; Luo, Jiang-Shan; Wu, Wei-Dong; Tang, Yong-Jian

    2016-02-01

    The residual stress in beryllium films fabricated on K9 substrates by using magnetron sputtering deposition is measured by using a curvature method and is theoretically estimated by using the Nix and Clemens (NC) model. The experimental results indicate that the 1.3-μm-thick film is always in a tensile state for pressure variations in the range from 0.4 to 1.2 Pa. When the sputtering gas pressure is increased, the average stress increases at first, after which it decreases by a remarkable amount. The observed descending trend of the tensile stress when the sputtering gas pressure is beyond 0.6 Pa is mainly attributed to the grain size in the film being larger than that in the film when the pressure is below 0.6 Pa. The maximal residual stress of 552 MPa at a sputtering gas pressure of 0.6 Pa is close to the tensile strength (550 MPa) of the corresponding beryllium bulk material and is about 8 times smaller than that calculated by using the N-C model. In addition, the surface morphologies of the as-fabricated films reveal fibrous grains while the cross-sectional morphologies are characterized by a coarsening of columnar grains. The measured electric resistivity of each film strongly depends on its porosity and the sizes of its grains.

  5. Effect of Weld Schedule on the Residual Stress Distribution of Boron Steel Spot Welds

    NASA Astrophysics Data System (ADS)

    Raath, N. D.; Norman, D.; McGregor, I.; Dashwood, R.; Hughes, D. J.

    2017-06-01

    Press-hardened boron steel has been utilized in anti-intrusion systems in automobiles, providing high strength and weight-saving potential through gage reduction. Boron steel spot welds exhibit a soft heat-affected zone which is surrounded by a hard nugget and outlying base material. This soft zone reduces the strength of the weld and makes it susceptible to failure. Additionally, different welding regimes lead to significantly different hardness distributions, making failure prediction difficult. Boron steel sheets, welded with fixed and adaptive schedules, were characterized. These are the first experimentally determined residual stress distributions for boron steel resistance spot welds which have been reported. Residual strains were measured using neutron diffraction, and the hardness distributions were measured on the same welds. Additionally, similar measurements were performed on spot welded DP600 steel as a reference material. A correspondence between residual stress and hardness profiles was observed for all welds. A significant difference in material properties was observed between the fixed schedule and adaptively welded boron steel samples, which could potentially lead to a difference in failure loads between the two boron steel welds.

  6. Effect of substrate preheating temperature and coating thickness on residual stress in plasma sprayed hydroxyapatite coating

    NASA Astrophysics Data System (ADS)

    Tang, Dapei

    2015-07-01

    A thermal-mechanical coupling model was developed based on thermal-elastic- plastic theory according the special process of plasma spraying Hydroxyapatite (HA) coating upon Ti-6Al-4V substrate. On the one hand, the classical Fourier transient heat conduction equation was modified by introducing the effect item of deformation on temperature, on the other hand, the Johnson-Cook model, suitable for high temperature and high strain rate conditions, was used as constitutive equation after considering temperature softening effect, strain hardening effect and strain rate reinforcement effect. Based on the above coupling model, the residual stress field within the HA coating was simulated by using finite element method (FEM). Meanwhile, the substrate preheating temperature and coating thickness on the influence of residual stress components were calculated, respectively. The failure modes of coating were also preliminary analyzed. In addition, in order to verify the reliability of calculation, the material removal measurement technique was applied to determine the residual stress of HA coating near the interface. Some important conclusions are obtained.

  7. Research on residual stress inside Fe-Mn-Si shape memory alloy coating by laser cladding processing

    NASA Astrophysics Data System (ADS)

    Ju, Heng; Lin, Cheng-xin; Zhang, Jia-qi; Liu, Zhi-jie

    2016-09-01

    The stainless Fe-Mn-Si shape memory alloy (SMA) coating was prepared on the surface of AISI 304 stainless steel. The principal residual stress measured by the mechanical hole-drilling method indicates that the Fe-Mn-Si SMA cladding specimen possesses a lower residual stress compared with the 304 stainless steel cladding specimen. The mean stress values of the former and the latter on 10-mm-thick substrate are 4.751 MPa and 7.399 MPa, respectively. What's more, their deformation values on 2-mm-thick substrate are about 0° and 15°, respectively. Meanwhile, the variation trend and the value of the residual stress simulated by the ANSYS finite element software consist with experimental results. The X-ray diffraction (XRD) pattern shows ɛ-martensite exists in Fe-Mn-Si SMA coating, which verifies the mechanism of low residual stress. That's the γ→ɛ martensite phase transformation, which relaxes the residual stress of the specimen and reduces its deformation in the laser cladding processing.

  8. Measuring stress: Uses and limitations

    SciTech Connect

    Suter, G.W. II

    1994-12-31

    The topic of the uses and limitations of measuring stress in the oceans is addressed. The use of the term stress in this context is ambiguous. Rather than assuming that stress is an actual measurable property of oceans, one may assume that the term refers to the complex of harmful things that is going on in the oceans. that is, it is a cover term for a complex of processes and states, many of which are unknown or undefined. The appeal of the term stress used in that way is very tempting. Considerable complexity results from the fact that the ocean consists of numerous and diverse species and ecosystems each of which have various properties that have some claim to protection. Another source of complexity is the diversity of factors which constitute threats to the environment. In evaluating the concepts of ecological risk assessment, there are sources of hazardous agents, there are receptors that are affected, and there is a process by which these interact termed exposure. As a result of exposure there is some probability that the actions of the sources have caused or will cause some effect on the receptor, the risk. Assessments may be source driven; they may attempt to determine the risks associated with a waste outfall. Assessments may also be effects driven; they may attempt to determine the cause of a die-off of marine mammals or determine the likelihood of a particular rise in sea-level. Finally, they may be exposure driven. Each of these components of the causal chain might serve as measures of stress.

  9. Measuring stress variation with depth using Barkhausen signals

    NASA Astrophysics Data System (ADS)

    Kypris, O.; Nlebedim, I. C.; Jiles, D. C.

    2016-06-01

    Magnetic Barkhausen noise analysis (BNA) is an established technique for the characterization of stress in ferromagnetic materials. An important application is the evaluation of residual stress in aerospace components, where shot-peening is used to strengthen the part by inducing compressive residual stresses on its surface. However, the evaluation of the resulting stress-depth gradients cannot be achieved by conventional BNA methods, where signals are interpreted in the time domain. The immediate alternative of using x-ray diffraction stress analysis is less than ideal, as the use of electropolishing to remove surface layers renders the part useless after inspection. Thus, a need for advancing the current BNA techniques prevails. In this work, it is shown how a parametric model for the frequency spectrum of Barkhausen emissions can be used to detect variations of stress along depth in ferromagnetic materials. Proof of concept is demonstrated by inducing linear stress-depth gradients using four-point bending, and fitting the model to the frequency spectra of measured Barkhausen signals, using a simulated annealing algorithm to extract the model parameters. Validation of our model suggests that in bulk samples the Barkhausen frequency spectrum can be expressed by a multi-exponential function with a dependence on stress and depth. One practical application of this spectroscopy method is the non-destructive evaluation of residual stress-depth profiles in aerospace components, thus helping to prevent catastrophic failures.

  10. Processing effects for integrated PZT: Residual stress, thickness, and dielectric properties

    NASA Astrophysics Data System (ADS)

    Ong, Ryan Jason

    This dissertation focuses on the integration of lead zirconate titanate (PZT) films on Pt/Ti/SiO2//Si, and the effect of on properties. Direct deposition of PZT on Si will lead to on-chip power capacitors, non-volatile memory cells, and vibration sensors. However, previous research indicates that the dielectric, ferroelectric and piezoelectric response characteristics for the devices are often inferior to bulk specimens. Property variations have been attributed to changes in several major variables including, chemical composition, phase content, grain size, crystallographic orientation, film thickness, and stress, each of which, in turn, can depend on processing. The first goal of this work was to design a sol-gel processing methodology to control all major variables except film thickness and stress, thus isolating their respective effects on properties. All specimens were verified to be of the Pb(Zr0.53Ti0.47)O3 composition, in the perovskite structure, with a constant grain size of 110nm, and with (111) fiber texture. PZT film thickness was varied from 95nm to 500nm and residual stress was measured to be either 150 or 180MPa, biaxial tensile, depending on thickness. These specimens allowed for new insights into the fundamental differences between bulk materials and thin films. A series-capacitor model accounted for the observed dilution in room-temperature K from >900 to ˜600 as film thickness decreased, but could not account for the absence of the expected dielectric anomaly at high temperatures. Instead, a stress-induced distributed phase transformation related to the polycrystalline nature of the film was proposed to account for the observed behavior. Residual stress reduced the spontaneous polarization values in these specimens to 32muC/cm 2 from the predicted stress-free value of 50muC/cm2. An increase in coercive field was attributed to interfacial capacitance and residual stress, whereas a decrease of 30MPa tensile stress resulted in an increase of d33

  11. Microstructure, Hardness, and Residual Stress Distributions in T-Joint Weld of HSLA S500MC Steel

    NASA Astrophysics Data System (ADS)

    Frih, Intissar; Montay, Guillaume; Adragna, Pierre-Antoine

    2017-03-01

    This paper investigates the characterization of the microstructure, hardness, and residual stress distributions of MIG-welded high-strength low-alloy S500MC steel. The T-joint weld for 10-mm-thick plates was joined using a two passes MIG welding technology. The contour method was performed to measure longitudinal welding residual stress. The obtained results highlighted a good correlation between the metallurgical phase constituents and hardness distribution within the weld zones. In fact, the presence of bainite and smaller ferrite grain size in the weld-fusion zone might be the reason for the highest hardness measured in this region. A similar trend of the residual stress and hardness distributions was also obtained.

  12. Microstructure, Hardness, and Residual Stress Distributions in T-Joint Weld of HSLA S500MC Steel

    NASA Astrophysics Data System (ADS)

    Frih, Intissar; Montay, Guillaume; Adragna, Pierre-Antoine

    2017-01-01

    This paper investigates the characterization of the microstructure, hardness, and residual stress distributions of MIG-welded high-strength low-alloy S500MC steel. The T-joint weld for 10-mm-thick plates was joined using a two passes MIG welding technology. The contour method was performed to measure longitudinal welding residual stress. The obtained results highlighted a good correlation between the metallurgical phase constituents and hardness distribution within the weld zones. In fact, the presence of bainite and smaller ferrite grain size in the weld-fusion zone might be the reason for the highest hardness measured in this region. A similar trend of the residual stress and hardness distributions was also obtained.

  13. Overcoming residual stresses and machining distortion in the production of aluminum alloy satellite boxes.

    SciTech Connect

    Younger, Mandy S.; Eckelmeyer, Kenneth Hall

    2007-11-01

    Distortion frequently occurs during machining of age hardening aluminum alloys due to residual stresses introduced during the quenching step in the heat treatment process. This report quantifies, compares, and discusses the effectiveness of several methods for minimizing residual stresses and machining distortion in aluminum alloys 7075 and 6061.

  14. Prediction and Optimization of Residual Stresses on Machined Surface and Sub-Surface in MQL Turning

    NASA Astrophysics Data System (ADS)

    Ji, Xia; Zou, Pan; Li, Beizhi; Rajora, Manik; Shao, Yamin; Liang, Steven Y.

    Residual stress in the machined surface and subsurface is affected by materials, machining conditions, and tool geometry and can affect the component life and service quality significantly. Empirical or numerical experiments are commonly used for determining residual stresses but these are very expensive. There has been an increase in the utilization of minimum quantity lubrication (MQL) in recent years in order to reduce the cost and tool/part handling efforts, while its effect on machined part residual stress, although important, has not been explored. This paper presents a hybrid neural network that is trained using Simulated Annealing (SA) and Levenberg-Marquardt Algorithm (LM) in order to predict the values of residual stresses in cutting and radial direction on the surface and within the work piece after the MQL face turning process. Once the ANN has successfully been trained, an optimization procedure, using Genetic Algorithm (GA), is applied in order to find the best cutting conditions in order to minimize the surface tensile residual stresses and maximize the compressive residual stresses within the work piece. The optimization results show that the usage of MQL decreases the surface tensile residual stresses and increases the compressive residual stresses within the work piece.

  15. Residual stress and damage-induced critical fracture on CO2 laser treated fused silica

    SciTech Connect

    Matthews, M; Stolken, J; Vignes, R; Norton, M

    2009-11-02

    Localized damage repair and polishing of silica-based optics using mid- and far-IR CO{sub 2} lasers has been shown to be an effective method for increasing optical damage threshold in the UV. However, it is known that CO{sub 2} laser heating of silicate surfaces can lead to a level of residual stress capable of causing critical fracture either during or after laser treatment. Sufficient control of the surface temperature as a function of time and position is therefore required to limit this residual stress to an acceptable level to avoid critical fracture. In this work they present the results of 351 nm, 3 ns Gaussian damage growth experiments within regions of varying residual stress caused by prior CO{sub 2} laser exposures. Thermally stressed regions were non-destructively characterized using polarimetry and confocal Raman microscopy to measure the stress induced birefringence and fictive temperature respectively. For 1 {approx} 40s square pulse CO{sub 2} laser exposures created over 0.5-1.25 kW/cm{sup 2} with a 1-3 mm 1/e{sup 2} diameter beam (T{sub max} {approx} 1500-3000 K), the critical damage site size leading to fracture increases weakly with peak temperature, but shows a stronger dependence on cooling rate, as predicted by finite element hydrodynamics simulations. Confocal micro-Raman was used to probe structural changes to the glass over different thermal histories and indicated a maximum fictive temperature of 1900K for T{sub max} {ge} 2000 K. The effect of cooling rate on fictive temperature caused by CO{sub 2} laser heating are consistent with finite element calculations based on a Tool-Narayanaswamy relaxation model.

  16. Effects of weld residual stresses on crack-opening area analysis of pipes for LBB applications

    SciTech Connect

    Dong, P.; Rahman, S.; Wilkowski, G.

    1997-04-01

    This paper summarizes four different studies undertaken to evaluate the effects of weld residual stresses on the crack-opening behavior of a circumferential through-wall crack in the center of a girth weld. The effect of weld residual stress on the crack-opening-area and leak-rate analyses of a pipe is not well understood. There are no simple analyses to account for these effects, and, therefore, they are frequently neglected. The four studies involved the following efforts: (1) Full-field thermoplastic finite element residual stress analyses of a crack in the center of a girth weld, (2) A comparison of the crack-opening displacements from a full-field thermoplastic residual stress analysis with a crack-face pressure elastic stress analysis to determine the residual stress effects on the crack-opening displacement, (3) The effects of hydrostatic testing on the residual stresses and the resulting crack-opening displacement, and (4) The effect of residual stresses on crack-opening displacement with different normal operating stresses.

  17. Compressive residual stress relaxation in hardened steel during cyclic and static load

    NASA Astrophysics Data System (ADS)

    Cseh, D.; Mertinger, V.

    2017-05-01

    The benefits of applied compressive residual stress on fatigue properties of materials is a well-known phenomenon, but not well described in all respects. The fatigue life and the fatigue limit could be improved by targeted created compressive residual stress in the surface layers therefore, diversified surface compressing methods are developed and used in the engineering industry. The relaxation of the compressive residual stress state during a cyclic and static load is determinative for the life time of a componenet. Compressive stress relaxation was experimentally determined during the cyclic and static load. The compressive residual stress was induced by shot penning on the surface of stainless steel, micro alloyed high strength steel and hardened steel specimens. The residual stress state was investigated nondestructively by X-ray diffraction method then these specimens were load. After a certain number of cycles the fatigue load was stopped and the residual stress state was recorded again and again until fracture. To investigate the relaxation process during static load a four-point bending bench was used. The compressive residual stress relaxation was correlated to the applied fatigue stress level, the cycle number the quality of alloys.

  18. Effects of weld residual stresses on crack-opening area analysis of pipes for LBB applications

    SciTech Connect

    Dong, P.; Rahman, S.; Wilkowski, G.; Bouchard, J.; Chivers, T.; Brickstad, B.; Bergman, M.

    1996-12-01

    This paper summarizes four different studies undertaken to evaluate the effects of weld residual stresses on the crack-opening behavior of a circumferential through-wall crack in the center of a girth weld. The effect of weld residual stress on the crack-opening-area and leak-rate analyses of a pipe is not well understood. There are no simple analyses to account for these effects, and therefore, they are frequently neglected. The four studies involved the following efforts: (1) full-field thermoplastic finite element residual stress analyses of a crack in the center of a girth weld; (2) a comparison of the crack-opening displacements from a full-field thermoplastic residual stress analysis with a crack-face pressure elastic stress analysis to determine the residual stress effects on the crack-opening displacements; (3) the effects of hydrostatic testing on the residual stresses and the resulting crack-opening displacement; and (4) the effect of residual stresses on crack-opening displacement with different normal operating stresses.

  19. The Crack-contact and the Free End Problem for a Strip Under Residual Stress

    NASA Technical Reports Server (NTRS)

    Bakioglu, M.; Erdogan, F.

    1976-01-01

    The plane problem for an infinite strip with two edge cracks under a given state of residual stress is considered. The residual stress is compressive near and at the surfaces and tensile in the interior of the strip. If the crack is deep enough to penetrate into the tensile zone, then the problem is one of crack-contact problem in which the depth of the contact area is an unknown which depends on the crack depth and the residual stress profile. The problem has applications to the static fatigue of glass plates and is solved for three typical residual stress profiles. In the limiting case of the crack crossing the entire plate thickness, the problem becomes a stress-free end problem for a semi-infinite strip under a given residual stress state away from the end. This is a typical stress diffusion problem in which decay behavior of the residual stress near and the nature of the normal displacement at the end of the semi-infinite strip are of special interest. For two typical residual stress states the solution is obtained, and some numerical results are given.

  20. Effect of residual stress on modal patterns of MEMS vibratory gyroscope

    SciTech Connect

    Dutta, Shankar Panchal, Abha; Kumar, Manoj; Pal, Ramjay; Bhan, R. K.

    2016-04-13

    Deep boron diffusion often induces residual stress in bulk micromachined MEMS structures, which may affect the MEMS devices operation. In this study, we studied the modal patterns of MEMS vibratory gyroscope under the residual stress (100 – 1000 MPa). Modal patterns and modal frequencies of the gyro are found to be dependent on the residual stress values. Without any residual stress, the modal frequencies drive and sense modeswere found to be 20.06 kHz and 20.36 kHz respectively. In presence of 450 MPa residual stress, the modal frequencies of the drive and sense modes were changed to 42.75 kHz and 43.07 kHz respectively.

  1. Effect of residual stress on modal patterns of MEMS vibratory gyroscope

    NASA Astrophysics Data System (ADS)

    Dutta, Shankar; Panchal, Abha; Kumar, Manoj; Pal, Ramjay; Bhan, R. K.

    2016-04-01

    Deep boron diffusion often induces residual stress in bulk micromachined MEMS structures, which may affect the MEMS devices operation. In this study, we studied the modal patterns of MEMS vibratory gyroscope under the residual stress (100 - 1000 MPa). Modal patterns and modal frequencies of the gyro are found to be dependent on the residual stress values. Without any residual stress, the modal frequencies drive and sense modeswere found to be 20.06 kHz and 20.36 kHz respectively. In presence of 450 MPa residual stress, the modal frequencies of the drive and sense modes were changed to 42.75 kHz and 43.07 kHz respectively.

  2. Influence of residual thermal stresses and geometric parameters on stress and electric fields in multilayer ceramic capacitors under electric bias

    NASA Astrophysics Data System (ADS)

    Jiang, Wu-Gui; Feng, Xi-Qiao; Nan, Ce-Wen

    2008-07-01

    The stress and electric fields in multilayer ceramic capacitors (MLCCs) under an applied electric bias were investigated by using a three-dimensional finite element model of ferroelectric ceramics. A coupled thermal-mechanical analysis was first made to calculate the residual thermal stress induced by the sintering process, and then a coupled electrical-mechanical analysis was performed to predict the total stress distribution in the MLCCs under a representative applied electric bias. The effects of the number of dielectric layers, the single layer thickness as well as the residual thermal stresses on the total stresses were all examined. The numerical results show that the residual thermal stress induced by the sintering process has a significant influence on the contribution of the total stresses and, therefore, should be taken into account in the design and evaluation of MLCC devices.

  3. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

    DOE PAGES

    Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; ...

    2015-09-08

    This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stirmore » zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.« less

  4. Residual stress in nano-structured stainless steel (AISI 316L) prompted by Xe+ ion bombardment at different impinging angles

    NASA Astrophysics Data System (ADS)

    Cucatti, S.; Droppa, R.; Figueroa, C. A.; Klaus, M.; Genzel, Ch.; Alvarez, F.

    2016-10-01

    The effect of low energy (<1 keV) xenon (Xe+) ion bombardment on the residual stress of polycrystalline iron alloy (AISI 316L steel) is reported. The results take into account the influence of the ion incident angle maintaining constant all other bombarding parameters (i.e., ion energy and current density, temperature, and doses). The bombarded surface topography shows that ions prompt the formation of nanometric regular patterns on the surface crystalline grains and stressing the structure. The paper focalizes on the study of the surface residual stress state stemming from the ion bombardment studied by means of the "sin2 ψ" and "Universal Plot" methods. The analysis shows the absence of shear stress in the affected material region and the presence of compressive in-plane residual biaxial stress (˜200 MPa) expanding up to ˜1 μm depth for all the studied samples. Samples under oblique bombardment present higher compressive stress values in the direction of the projected ion beam on the bombarded surface. The absolute value of the biaxial surface stress difference (σ11-σ22) increases on ion impinging angles, a phenomenon associated with the momentum transfer by the ions. The highest stress level was measured for ion impinging angles of 45° ( σ 11 = -380 ± 10 MPa and σ 22 = -320 ± 10 MPa). The different stresses obtained in the studied samples do not affect significantly the formation of characteristic surface patterns.

  5. Residual Stress Determination for A Ferritic Steel Weld Plate

    SciTech Connect

    Wang, D.-Q.; Hubbard, C.R.; Spooner, S.

    1999-10-01

    The primary objective of this experiment is to demonstrate the capability of neutron diffraction technique to reproducibly map residual strains in a ferritic steel weld. The objective includes the identification of corrections for variations in metal composition due to the welding process which produces changes in lattice parameter that are not due to mechanical effects. The second objective is to develop and demonstrate a best practice for neutron diffraction strain mapping of steel welds. The appropriate coordinate system for the measurement of a weld, which is strongly distorted from planar geometry, has to be defined. The coordinate system is important in determining the procedures for mounting and positioning of the weld so that mapping details, especially in regions of high gradients, can be conveniently inter-compared between laboratories.

  6. Numerical Analysis of Welding Residual Stress Relaxation in High-Strength Multilayer Weldment Under Fatigue Loads

    NASA Astrophysics Data System (ADS)

    Yi, Hui-Jun; Lee, Yong-Jun

    2017-08-01

    The primary purpose of this investigation was to study welding residual stress relaxation by repeated loading. A coupling finite element analysis model for prediction of the welding residual stress and the mechanical stress relaxation after external repeated loads was presented. The accuracy of this model was verified through experiments. Also, it is found that the residual stress of weldment is relaxed by external loads, and the greatest amount of relaxation was obtained by early repeated loads. As the repetition count increased, the amount of relaxation became smaller than the amount of relaxation in the early stage.

  7. Detection and measurement of organic lampricide residues

    USGS Publications Warehouse

    Daniels, Stacy L.; Kempe, Lloyd L.; Billy, Thomas J.; Beeton, Alfred M.

    1965-01-01

    The selective lampricide, 3-trifluoromethyl-4-nitrophenol (TFM), and its synergist, 5,2'-dichloro-4'-nitrosalicylanilide (DCN), are separable from natural waters by anion exchange. The adsorbed compounds can then be recovered from the resin as concentrates by elution with selective solvent mixtures. Measurements of the amounts of lampricides in the final concentrates can be made colorimetrically at 395 mI? for TFM and at 530 mI? for the safranin complex of DCN. TFM has also been separated for quantitative determination from homogenates of whole fish. The fish is first macerated in a blender and then hydrolyzed in hot, 3 N hydrochloric acid. The amount of background color, due to certain components of the fish in the hydrolysate, is reduced by one or a combination of three methods: (1) a series of three extractions with ether, methylene chloride, and benzene; (2) cation exchange followed by methylene chloride extraction; or (3) ether extraction followed by anion exchange and subsequent desorption with amyl acetate-acetic acid.

  8. Comparison of residual stresses in Inconel 718 simple parts made by electron beam melting and direct laser metal sintering

    SciTech Connect

    Kolbus, Lindsay M.; Payzant, E. Andrew; Cornwell, Paris A.; Watkins, Thomas R.; Babu, Sudarsanam Suresh; Dehoff, Ryan R.; Duty, Chad E.; Lorenz, M.; Ovchinnikova, O. S.

    2015-01-10

    Residual stress profiles were mapped using neutron diffraction in two simple prism builds of Inconel 718: one fabricated with electron beam melting and the other with direct laser sintering. Spatially indexed stress-free cubes were obtained by EDM sectioning equivalent prisms of similar shape. The (311) interplanar spacing examined for the EDM sectioned sample was compared to the interplanar spacings calculated to fulfill force and moment balance. We have shown that Applying force and moment balance is a necessary supplement to the measurements for the stress-free cubes with respect to accurate stress calculations in additively manufactured components. Furthermore, our work has shown that residual stresses in electron beam melting parts are much smaller than that of direct laser metal sintering parts.

  9. Comparison of residual stresses in Inconel 718 simple parts made by electron beam melting and direct laser metal sintering

    DOE PAGES

    Kolbus, Lindsay M.; Payzant, E. Andrew; Cornwell, Paris A.; ...

    2015-01-10

    Residual stress profiles were mapped using neutron diffraction in two simple prism builds of Inconel 718: one fabricated with electron beam melting and the other with direct laser sintering. Spatially indexed stress-free cubes were obtained by EDM sectioning equivalent prisms of similar shape. The (311) interplanar spacing examined for the EDM sectioned sample was compared to the interplanar spacings calculated to fulfill force and moment balance. We have shown that Applying force and moment balance is a necessary supplement to the measurements for the stress-free cubes with respect to accurate stress calculations in additively manufactured components. Furthermore, our work hasmore » shown that residual stresses in electron beam melting parts are much smaller than that of direct laser metal sintering parts.« less

  10. Study on the residual stress relaxation in girth-welded steel pipes under bending load using diffraction methods

    DOE PAGES

    Hempel, Nico; Bunn, Jeffrey R.; Nitschke-Pagel, Thomas; ...

    2017-02-02

    This research is dedicated to the experimental investigation of the residual stress relaxation in girth-welded pipes due to quasi-static bending loads. Ferritic-pearlitic steel pipes are welded with two passes, resulting in a characteristic residual stress state with high tensile residual stresses at the weld root. Also, four-point bending is applied to generate axial load stress causing changes in the residual stress state. These are determined both on the outer and inner surfaces of the pipes, as well as in the pipe wall, using X-ray and neutron diffraction. Focusing on the effect of tensile load stress, it is revealed that notmore » only the tensile residual stresses are reduced due to exceeding the yield stress, but also the compressive residual stresses for equilibrium reasons. Furthermore, residual stress relaxation occurs both parallel and perpendicular to the applied load stress.« less

  11. Statistical measures on residue-level protein structural properties.

    PubMed

    Huang, Yuanyuan; Bonett, Stephen; Kloczkowski, Andrzej; Jernigan, Robert; Wu, Zhijun

    2011-07-01

    The atomic-level structural properties of proteins, such as bond lengths, bond angles, and torsion angles, have been well studied and understood based on either chemistry knowledge or statistical analysis. Similar properties on the residue-level, such as the distances between two residues and the angles formed by short sequences of residues, can be equally important for structural analysis and modeling, but these have not been examined and documented on a similar scale. While these properties are difficult to measure experimentally, they can be statistically estimated in meaningful ways based on their distributions in known proteins structures. Residue-level structural properties including various types of residue distances and angles are estimated statistically. A software package is built to provide direct access to the statistical data for the properties including some important correlations not previously investigated. The distributions of residue distances and angles may vary with varying sequences, but in most cases, are concentrated in some high probability ranges, corresponding to their frequent occurrences in either α-helices or β-sheets. Strong correlations among neighboring residue angles, similar to those between neighboring torsion angles at the atomic-level, are revealed based on their statistical measures. Residue-level statistical potentials can be defined using the statistical distributions and correlations of the residue distances and angles. Ramachandran-like plots for strongly correlated residue angles are plotted and analyzed. Their applications to structural evaluation and refinement are demonstrated. With the increase in both number and quality of known protein structures, many structural properties can be derived from sets of protein structures by statistical analysis and data mining, and these can even be used as a supplement to the experimental data for structure determinations. Indeed, the statistical measures on various types of

  12. Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

    NASA Technical Reports Server (NTRS)

    Oswald, Fred B.; Zaretsky, Erwin V.; Poplawski, Joseph V.

    2015-01-01

    Rolling-element bearings operated at high speed or high vibration may require a tight interference fit between the bore of the bearing and shaft to prevent rotation of the bearing bore around the shaft and fretting damage at the interfaces. Previous work showed that the hoop stresses resulting from tight interference fits can reduce bearing lives by as much as 65 percent. Where tight interference fits are required, case-carburized steel such as AISI 9310 or M50 NiL is often used because the compressive residual stresses inhibit subsurface crack formation and the ductile core inhibits inner-ring fracture. The presence of compressive residual stress and its combination with hoop stress also modifies the Hertz stress-life relation. This paper analyzes the beneficial effect of residual stresses on rolling-element bearing fatigue life in the presence of high hoop stresses for three bearing steels. These additional stresses were superimposed on Hertzian principal stresses to calculate the inner-race maximum shearing stress and the resulting fatigue life of the bearing. The load-life exponent p and Hertz stress-life exponent n increase in the presence of compressive residual stress, which yields increased life, particularly at lower stress levels. The Zaretsky life equation is described and is shown to predict longer bearing lives and greater load- and stress-life exponents, which better predicts observed life of bearings made from vacuum-processed steel.

  13. μ-Raman studies of residual stress in SiC MEMS

    NASA Astrophysics Data System (ADS)

    Zingarelli, Chris

    2005-04-01

    μ-Raman spectroscopy is used to measure residual stress in single-crystal, 6H-SiC used in MEMS devices. These structures are bulk micro-machined by back etching a 250-μm-thick, single-crystal 6H-SiC wafer to form a 50-μm thick diaphragm. A Wheatstone bridge, patterned of piezoresistive elements, is formed across the membrane from a 5-μm, 6H-SiC epilayer; the output of the bridge is proportional to the flexure of the MEMS diaphragm. μ-Raman spectroscopy was performed with an Ar^+ laser (λ = 514.5 nm). By employing an incorporated piezoelectric stage with submicron positioning capabilities along with the Raman spectral acquisition, spatial scans revealed areas in the MEMS structures that contain residual stress. Shifts in the transverse optical (TO) Stokes peaks of up to 2 cm-1 along the edge of the diaphragm and through the piezoresistors indicate significant material strain induced by the MEMS fabrication process. The phonon deformation potential was measured to quantify the material stress as a function of the shift in the Raman peak position.

  14. Study of Traverse Speed Effects on Residual Stress State and Cavitation Erosion Behavior of Arc-Sprayed Aluminum Bronze Coatings

    NASA Astrophysics Data System (ADS)

    Hauer, Michél; Henkel, Knuth Michael; Krebs, Sebastian; Kroemmer, Werner

    2017-01-01

    Within a research project regarding cavitation erosion-resistant coatings, arc spraying was used with different traverse speeds to influence heat transfer and the resulting residual stress state. The major reason for this study is the lack of knowledge concerning the influence of residual stress distribution on mechanical properties and coating adhesion, especially with respect to heterogeneous aluminum bronze alloys. The materials used for spray experiments were the highly cavitation erosion-resistant propeller alloys CuAl9Ni5Fe4Mn (Ni-Al-Bronze) and CuMn13Al8Fe3Ni2 (Mn-Al-Bronze). Analyses of cavitation erosion behavior were carried out to evaluate the suitability for use in marine environments. Further microstructural, chemical and mechanical analyses were realized to examine adhesive and cohesive coating properties. Residual stress distribution was measured by modified hole drilling method using electronic speckle pattern interferometry (ESPI). It was found that the highest traverse speed led to higher tensile residual stresses near the surface and less cavitation erosion resistance of the coatings. Moreover, high oxygen affinity of main alloying element aluminum was identified to severely influence the microstructures by the formation of large oxides and hence the coating properties. Overall, Mn-Al-Bronze coatings showed lower residual stresses, a more homogeneous pore and oxide distribution and less material loss by cavitation than Ni-Al-Bronze coatings.

  15. Study on the effect of the surface treatment on the residual stress gradient in silicon carbide (SiC) reinforced aluminum metal matrix composites

    SciTech Connect

    Lu, J.; Miege, B.; Flavenot, J.; Thery, S. Groupe Usinor Sacilor, Firminy )

    1990-01-01

    In this work, the residual stresses induced on SiC-reinforced MMCs by the manufacturing processes (machining, surface finishing, and surface treatment) were investigated using an incremental hole-drilling method to measure the macroscopic residual stress gradient in depth and X-ray diffraction method to study the surface residual stresses in matrix. Three aluminum matrices (2024, 2124, and 6061) with different proportions of SiC fiber were tested, and the effects of the heat treatment, machining, and shot-peening treatment on the residual stress distribution of the materials were analyzed and compared. Results show that it is possible to optimize the residual stress distribution of MCC materials with adequate posttreatment. 14 refs.

  16. Residual waste volume measurement for Hanford underground storage tanks

    SciTech Connect

    Berglin, E.J.

    1996-08-21

    The Acquire Commercial Technology for Retrieval program seeks commercial solutions to measure any waste residual (i.e., heel)left after waste retrieval operations of underground radioactive storage tanks. The technology identified should operate in a range of waste depth thickness of 0 - 6 inches. This report provides a description of the need, requirements, and constraints for the residual waste volume measurement system; describes a logical approach to measuring waste volume; provides a brief review and assessment of available technologies; and outlines a set of integrated tests that will evaluate the performance of candidate technologies.

  17. Residual stresses in boron/tungsten and boron/carbon fibers

    NASA Technical Reports Server (NTRS)

    Behrendt, D. R.

    1977-01-01

    By measuring the change in fracture stress of 203 micrometer diameter fibers of boron on tungsten (B/W) as a function of fiber diameter as reduced by chemical etching, it is shown that the flaws which limit B/W fiber strength are located at the surface and in the tungsten boride core. After etching to a diameter of 188 micrometers m virtually all fiber fractures were caused by core flaws, the average strength being 4.50 GN/sq m. If both the surface and core flaws are removed, the fracture strength, limited by flaws in the boron itself, is approximately 6.89 GN/sq m. This was measured on B/W fibers which were split longitudinally and had their cores removed by chemical etching. The longitudinal residual stress distribution was determined for 102 micrometer diameter B/W and B/C fibers.

  18. Residual Stress Effect on the Delayed Fracture of Twinning-Induced Plasticity Steels

    NASA Astrophysics Data System (ADS)

    Kim, Jung Gi; Yoon, Jae Ik; Baek, Seung Mi; Seo, Min Hong; Cho, Won Tae; Chin, Kwang-Geun; Lee, Sunghak; Kim, Hyoung Seop

    2017-03-01

    Residual stress effect of the deep drawn TWIP steel on delayed fracture was investigated. Microstructural features of the TWIP steels did not change after stress relief annealing, while the elastic lattice strain dropped to 0.0007. Delayed fracture of the drawn TWIP steel occurred after 203 hours of HCl immersion testing, but did not occur in the annealed one. It is clear that residual stress after the drawing is the primary reason for the delayed fracture of TWIP steels.

  19. Residual Stress Effect on the Delayed Fracture of Twinning-Induced Plasticity Steels

    NASA Astrophysics Data System (ADS)

    Kim, Jung Gi; Yoon, Jae Ik; Baek, Seung Mi; Seo, Min Hong; Cho, Won Tae; Chin, Kwang-Geun; Lee, Sunghak; Kim, Hyoung Seop

    2017-06-01

    Residual stress effect of the deep drawn TWIP steel on delayed fracture was investigated. Microstructural features of the TWIP steels did not change after stress relief annealing, while the elastic lattice strain dropped to 0.0007. Delayed fracture of the drawn TWIP steel occurred after 203 hours of HCl immersion testing, but did not occur in the annealed one. It is clear that residual stress after the drawing is the primary reason for the delayed fracture of TWIP steels.

  20. Residual stress and fracture characteristics of zirconia/metal(Ni, SUS304) functionally gradient materials

    SciTech Connect

    Jung, Yeon-Gil; Choi, Sung-Churl; Paik, Un-Gyu

    1995-09-01

    To analyze the residual stress and the fracture behavior of FGMs. disc-type TZP/Ni- and TZP/SUS304-FGM were hot passed, and compared with MM& The continuous interface and the microstructure of FGMs were characterized with EPMA, optical microscopy and SEM. The defect-like cracks in the FGMs induced by the preferential shear stress have been shown to cause fracture. This fact has well corresponded to the analysis of the residual stress distribution by FEM.

  1. Effects of silicon-on-insulator substrate on the residual stress within 3C-SiC/Si thin films

    NASA Astrophysics Data System (ADS)

    Park, J.-H.; Kim, J. H.; Kim, Y.; Lee, B.-T.; Jang, S.-J.; Moon, C.-K.; Song, H.-J.

    2003-09-01

    Single-crystalline 3C-SiC heteroepitaxial layers were grown on silicon-on-insulator (SOI) and Si wafers, to investigate effects of SOI substrates on the film quality. Residual stress measurement using a laser scan method and the Raman scattering spectroscopy indicated that internal stress within SiC films on SOI were indeed reduced, when compared with that of SiC films on Si.

  2. Compressional residual stress in Bastogne boudins revealed by synchrotron X-ray microdiffraction

    SciTech Connect

    Chen, Kai; Kunz, Martin; Li, Yao; Zepeda-Alarcon, Eloisa; Sintubin, Manuel; Wenk, Hans-Rudolf

    2016-06-22

    Lattice distortions in crystals can be mapped at the micron scale using synchrotron X-ray Laue microdiffraction (μXRD). From lattice distortions the shape and orientation of the elastic strain tensor can be derived and interpreted in terms of residual stress. We apply the new method to vein quartz from the original boudinage locality at Bastogne, Belgium. Furthermore, a long-standing debate surrounds the kinematics of the Bastogne boudins. The μXRD measurements reveal a shortening residual elastic strain, perpendicular to the vein wall, corroborating the model that the Bastogne boudins formed by layer-parallel shortening and not by layer-parallel extension, as is in the geological community generally inferred by the process of boudinage.

  3. Compressional residual stress in Bastogne boudins revealed by synchrotron X-ray microdiffraction

    DOE PAGES

    Chen, Kai; Kunz, Martin; Li, Yao; ...

    2016-06-22

    Lattice distortions in crystals can be mapped at the micron scale using synchrotron X-ray Laue microdiffraction (μXRD). From lattice distortions the shape and orientation of the elastic strain tensor can be derived and interpreted in terms of residual stress. We apply the new method to vein quartz from the original boudinage locality at Bastogne, Belgium. Furthermore, a long-standing debate surrounds the kinematics of the Bastogne boudins. The μXRD measurements reveal a shortening residual elastic strain, perpendicular to the vein wall, corroborating the model that the Bastogne boudins formed by layer-parallel shortening and not by layer-parallel extension, as is in themore » geological community generally inferred by the process of boudinage.« less

  4. Compressional residual stress in Bastogne boudins revealed by synchrotron X-ray microdiffraction

    NASA Astrophysics Data System (ADS)

    Chen, Kai; Kunz, Martin; Li, Yao; Zepeda-Alarcon, Eloisa; Sintubin, Manuel; Wenk, Hans-Rudolf

    2016-06-01

    Lattice distortions in crystals can be mapped at the micron scale using synchrotron X-ray Laue microdiffraction (μXRD). From lattice distortions the shape and orientation of the elastic strain tensor can be derived and interpreted in terms of residual stress. Here we apply the new method to vein quartz from the original boudinage locality at Bastogne, Belgium. A long-standing debate surrounds the kinematics of the Bastogne boudins. The μXRD measurements reveal a shortening residual elastic strain, perpendicular to the vein wall, corroborating the model that the Bastogne boudins formed by layer-parallel shortening and not by layer-parallel extension, as is in the geological community generally inferred by the process of boudinage.

  5. X-ray study of residual stresses in narrow groove TIG weldments. Final technical report, September 1979-March 1984

    SciTech Connect

    Ruud, C.O.; Pangborn, R.N.; Snoha, D.J.

    1985-01-01

    The residual stresses measured in this project in the plane of the plate rolling surface, in the heat-affected zone, adjacent and in a direction normal to the weld fusion line, are greater than those in a direction parallel to the weld fusion line. This is in contradiction to the observation that in single-pass welds the parallel stresses are greater. The maximum residual stresses observed in the weldment studied were nearly or at the yield strength; this stress level is comparable with that shown in welds from thin plates, but no greater; and was at the weld fusion line, or toe, of the weld. A double peak in the plots of stresses normal to the weld line on traverses normal to the weld on the rolled surface of the original plate was attributed to hardenability variation caused by the thermal cycling during multi-pass welding. The stress field of the narrow groove weldment is less extensive than what was predicted for V groove. Stress relief due to cutting the weldment through a plane normal to the weld line caused relief as far as 40% of the plate thickness. The weld repair caused severe perturbations to residual stress symmetry of the weldment.

  6. Modeling of microstructure and residual stress in cast iron calendar rolls

    SciTech Connect

    Jacot, A.; Maijer, D.; Cockcroft, S.

    2000-04-01

    A comprehensive mathematical model based on the commercial finite-element (FE) code ABAQUS has been developed to predict the evolution of temperature, microstructure, and residual stresses in cast iron castings. The thermal component of the model, applied in stage one of the analysis, is capable of simulating the formation of microstructure over a broad range of cooling conditions, including the formation of columnar white iron as well as equiaxed gray iron. To test the model, it has been evaluated against thermocouple and microstructural data collected from a reduced-scale calendar roll test casting. The model has been demonstrated to be able to predict the transition from columnar white iron to equiaxed gray iron which occurs approximately 20 mm below the outside surface of the roll test casting. In addition, the model is shown to be able to satisfactorily reproduce the evolution of temperature recorded from thermocouples embedded at various locations in the test casting. An elastic-plastic stress analysis, applied in the second stage of the analysis, was performed using the temperature history and the volume fraction of white and gray iron obtained with the thermal/microstructural model. The results were verified against residual stress measurements made at various locations along the outer-diameter (OD) surface of the roll. The elastic-plastic model accounts for the temperature-dependent plastic behavior of white and gray iron and the thermal dilatational behavior of white and gray iron, including volumetric expansion due to austenite decomposition and dilatational anisotropy in columnar white iron. The results of the mathematical analysis demonstrate that the residual stress distribution in full-scale calendar thermorolls cannot be deduced simply from knowledge of the microstructural distribution and basic dilatometric considerations, as is currently the practice in industry.

  7. Quasi-residual strain and moduli measurements in materials using embedded acoustic waveguides

    NASA Astrophysics Data System (ADS)

    Harrold, Ronald T.; Sanjana, Zal N.; Raju, Basavaraju B.

    1996-11-01

    Following the processing and manufacture of resin and composite parts and during their lifetime, the distribution of internal residual strain and any variations in moduli are generally unknown. Real-time information on these parameters would be valuable for improving material performance and reliability. It is believed that measurements related to material residual stresses or strain and moduli can be obtained by measuring the longitudinal wave velocities within acoustic waveguides (AWG) embedded within a material. The concept is that the wave velocities within embedded AWG are related to the material bulk modulus, density and Poisson's Ratio which are all in some degree related to the material state of cure, and finally the internal residual stresses. Based on this concept it is shown that the AWG of different diameters embedded within the same resin part of uniform internal stress distribution, the AWG wave velocities should vary in relation to the square root of the AWG diameter. Experimental results using AWG of 5, 10, 16, 20, 40 and 62 mil diameter Nichrome embedded within Shell 815 clear resin with optically measured uniform strain, demonstrate a direct relationship between AWG velocities and the square root of the AWG diameter. Consequently, it is reasoned that for a part with several embedded AWG, each of the same diameter, then differences in the AWG velocities would yield information on differences in the residual strain and moduli within the part.

  8. Status report. Characterization of Weld Residual Stresses on a Full-Diameter SNF Interim Storage Canister Mockup.

    SciTech Connect

    Enos, David; Bryan, Charles R.

    2015-08-01

    This report documents the mockup specifications and manufacturing processes; the initial cutting of the mockup into three cylindrical pieces for testing and the measured strain changes that occurred during the cutting process; and the planned weld residual stress characterization activities and the status of those activities.

  9. Measurement of Residual Flexibility for Substructures Having Prominent Flexible Interfaces

    NASA Technical Reports Server (NTRS)

    Tinker, Michael L.; Bookout, Paul S.

    1994-01-01

    Verification of a dynamic model of a constrained structure requires a modal survey test of the physical structure and subsequent modification of the model to obtain the best agreement possible with test data. Constrained-boundary or fixed-base testing has historically been the most common approach for verifying constrained mathematical models, since the boundary conditions of the test article are designed to match the actual constraints in service. However, there are difficulties involved with fixed-base testing, in some cases making the approach impractical. It is not possible to conduct a truly fixed-base test due to coupling between the test article and the fixture. In addition, it is often difficult to accurately simulate the actual boundary constraints, and the cost of designing and constructing the fixture may be prohibitive. For use when fixed-base testing proves impractical or undesirable, alternate free-boundary test methods have been investigated, including the residual flexibility technique. The residual flexibility approach has been treated analytically in considerable detail and has had limited frequency response measurements for the method. This concern is well-justified for a number of reasons. First, residual flexibilities are very small numbers, typically on the order of 1.0E-6 in/lb for translational diagonal terms, and orders of magnitude smaller for off-diagonal values. This poses difficulty in obtaining accurate and noise-free measurements, especially for points removed from the excitation source. A second difficulty encountered in residual measurements lies in obtaining a clean residual function in the process of subtracting synthesized modal data from a measured response function. Inaccuracies occur since modes are not subtracted exactly, but only to the accuracy of the curve fits for each mode; these errors are compounded with increasing distance from the excitation point. In this paper, the residual flexibility method is applied to a simple

  10. Synchrotron measurements of local microstructure and residual strains in ductile cast iron

    NASA Astrophysics Data System (ADS)

    Zhang, Y. B.; Andriollo, T.; Fæster, S.; Liu, W.; Sturlason, A.; Barabash, R.

    2017-07-01

    The local microstructure and distribution of thermally induced residual strains in ferrite matrix grains around an individual spherical graphite nodule in ductile cast iron (DCI) were measured using a synchrotron X-ray micro-diffraction technique. It is found that the matrix grains are deformed, containing dislocations and dislocation boundaries. Each of the residual strain components in the matrix grains exhibits a complex pattern along the circumferential direction of the nodule. Along the radial direction of the nodule, strain gradients from the interface to the grain interior are seen for some strain components, but only in some matrix grains. The observed residual strain patterns have been analysed by finite element modelling, and a comparison between the simulation and experiments is given. The present study of local residual stress by both experimental characterization and simulation provide much needed information for understanding the mechanical properties of DCI, and represent an important contribution for the microstructural design of new DCI materials.

  11. Simulation of Distortion and Residual Stress Development During Heat Treatment of Steel Castings

    SciTech Connect

    Beckermann, Christoph; Carlson, Kent

    2011-07-22

    Heat treatment and associated processing, such as quenching, are critical during high strength steel casting production. These processes must be managed closely to prevent thermal and residual stresses that may result in distortion, cracking (particularly after machining), re-work, and weld repair. The risk of casting distortion limits aggressive quenching that can be beneficial to the process and yield an improved outcome. As a result of these distortions, adjustments must be made to the casting or pattern design, or tie bars must be added. Straightening castings after heat treatments can be both time-consuming and expensive. Residual stresses may reduce a casting's overall service performance, possibly resulting in catastrophic failure. Stress relieving may help, but expends additional energy in the process. Casting software is very limited in predicting distortions during heat treatment, so corrective measures most often involve a tedious trial-and-error procedure. An extensive review of existing heat treatment residual stress and distortion modeling revealed that it is vital to predict the phase transformations and microstructure of the steel along with the thermal stress development during heat treatment. After reviewing the state-of-the-art in heat treatment residual stress and distortion modeling, an existing commercial code was selected because of its advanced capabilities in predicting phase transformations, the evolving microstructure and related properties along with thermal stress development during heat treatment. However, this software was developed for small parts created from forgings or machined stock, and not for steel castings. Therefore, its predictive capabilities for heat treatment of steel castings were investigated. Available experimental steel casting heat treatment data was determined to be of insufficient detail and breadth, and so new heat treatment experiments were designed and performed, casting and heat treating modified versions of

  12. Ultra-fast annealing to reduce the residual stress in ultra-thin chips using flash light

    NASA Astrophysics Data System (ADS)

    Jeon, Eun-Beom; Park, Junhong; Kim, Hak-Sung

    2014-04-01

    The continuing trend of miniaturization in electronic equipment includes demands for thinner and smaller semiconductor devices with higher performance. To ensure the reliability of electronic devices and to enable high-throughput packaging processes, the mechanical properties of ultra-thin chips need to be accurately understood. One important consideration is the residual stress generated during wafer thinning due to the shear force between the grinding wheel and polish pad; this stress can degrade the fracture strength of ultra-thin devices. To reduce this residual stress, we developed a flash light irradiation annealing technique, including optimization of the irradiation conditions of flash light energy, pulse number and pulse duration. The distributions of residual stresses within ultra-thin flash memory chips before and after the annealing were measured using Raman spectroscopy, and their fracture strength was measured using a ball-on-ring test. Also, transmission electron microscopy (TEM) analysis and beam transfer function tests were performed to investigate the changes in mechanical properties and changes to the silicon lattice effected by the annealing. The ultra-fast flash light annealing was found to reduce the residual stress of ultra-thin chips by 50%, thereby improving their fracture strength by 20% compared to unannealed chips.

  13. Feasibility of the Davidenkov method for investigation of hoop residual stresses in cold expanded cylinders

    NASA Astrophysics Data System (ADS)

    Skvortsov, V. F.; Arlyapov, A. Yu; Boznak, A. O.; Ogol, I. I.; Kim, A. B.

    2017-02-01

    Cold expansion of holes in hollow cylinders is accompanied by raise of residual stresses in the bulk of the cylinder, the largest of which are hoop residual stresses. Since hoop residual stresses affect critical performance characteristics, assessment of their nature and magnitude is one of the most significant engineering tasks. The most wide spread mechanical methods to define magnitude of hoop residual stresses are G Sachs and N N Davidenkov methods. The paper presents result of experimental studies by Sachs and Davidenkov methods of hoop residual stresses generated in hollow cylinders made of carbon steel AISI 1050 after cold expansion. It is shown that the shape of curves of hoop residual stresses calculated by the mentioned methods, depending on the hoop residual strain generated on the outer surface of the cylinder, can differ (strain is elastic) or coincide (strain is elastic-plastic). It was established that the absolute values of the stresses defined by the mentioned methods in the area adjacent to the hole differ by an average of 15%, and in the area adjacent to the outer surface differ by an average of 20%.

  14. Hydrogen Assisted Cracking in Pearlitic Steel Rods: The Role of Residual Stresses Generated by Fatigue Precracking

    PubMed Central

    Toribio, Jesús; Aguado, Leticia; Lorenzo, Miguel; Kharin, Viktor

    2017-01-01

    Stress corrosion cracking (SCC) of metals is an issue of major concern in engineering since this phenomenon causes many catastrophic failures of structural components in aggressive environments. SCC is even more harmful under cathodic conditions promoting the phenomenon known as hydrogen assisted cracking (HAC), hydrogen assisted fracture (HAF) or hydrogen embrittlement (HE). A common way to assess the susceptibility of a given material to HAC, HAF or HE is to subject a cracked rod to a constant extension rate tension (CERT) test until it fractures in this harsh environment. This paper analyzes the influence of a residual stress field generated by fatigue precracking on the sample’s posterior susceptibility to HAC. To achieve this goal, numerical simulations were carried out of hydrogen diffusion assisted by the stress field. Firstly, a mechanical simulation of the fatigue precracking was developed for revealing the residual stress field after diverse cyclic loading scenarios and posterior stress field evolution during CERT loading. Afterwards, a simulation of hydrogen diffusion assisted by stress was carried out considering the residual stresses after fatigue and the superposed rising stresses caused by CERT loading. Results reveal the key role of the residual stress field after fatigue precracking in the HAC phenomena in cracked steel rods as well as the beneficial effect of compressive residual stress. PMID:28772845

  15. Roller Burnishing - A Cold Working Tool to Reduce Weld Induced Residual Stress

    SciTech Connect

    John Martin

    2002-02-19

    The possibility of stress corrosion cracking (SCC) in regions of tensile residual stress introduced by weld deposited material has been a concern where environmental effects can reduce component life. Roller burnishing, a form of mechanical cold-working, has been considered as a means of providing for residual stress state improvements. This paper provides a computational evaluation of the roller burnishing process to address the permanent deformation needed to introduce a desirable residual stress state. The analysis uses a series of incrementally applied pressure loadings and finite element methodology to simulate the behavior of a roller burnishing tool. Various magnitudes of applied pressure loadings coupled with different size plates and boundary conditions are examined to assess the degree and depth of the residual compressive stress state after cold working. Both kinematic and isotropic hardening laws are evaluated.

  16. Crack prediction in EB-PVD thermal barrier coatings based on the simulation of residual stresses

    NASA Astrophysics Data System (ADS)

    Chen, J. W.; Zhao, Y.; Liu, S.; Zhang, Z. Z.; Ma, J.

    2016-07-01

    Thermal barrier coatings systems (TBCs) are widely used in the field of aerospace. The durability and insulating ability of TBCs are highly dependent on the residual stresses of top coatings, thus the investigation of the residual stresses is helpful to understand the failure mechanisms of TBCs. The simulation of residual stresses evolution in electron beam physical vapor deposition (EB-PVD) TBCs is described in this work. The interface morphology of TBCs subjected to cyclic heating and cooling is observed using scanning electron microscope (SEM). An interface model of TBCs is established based on thermal elastic-plastic finite method. Residual stress distributions in TBCs are obtained to reflect the influence of interfacial roughness. Both experimental and simulation results show that it is feasible to predict the crack location by stress analysis, which is crucial to failure prediction.

  17. Plasma sprayed hydroxyapatite coatings on titanium substrates. Part 1: Mechanical properties and residual stress levels.

    PubMed

    Tsui, Y C; Doyle, C; Clyne, T W

    1998-11-01

    Hydroxyapatite (HA) coatings have been sprayed on to substrates of Ti-6Al-4V, using a range of input power levels and plasma gas mixtures. Coatings have also been produced on substrates of mild steel and tungsten, in order to explore certain aspects of the mechanical behaviour of HA without the complication of yielding or creep in the substrate. Studies have been made of the phase constitution, porosity, degree of crystallinity, OH ion content, microstructure and surface roughness of the HA coatings. The Young's moduli in tension and in compression were evaluated by the cantilever beam bend test using a tungsten/HA composite beam. The flexural Young's modulus was determined using a free-standing deposit under the same test. Adhesion was characterised using the single-edge notch-bend test; this is considered superior to the tensile bond strength test in common use. Measured interfacial fracture energies were of the order 1-10 J m(-2). Stress levels were investigated using specimen curvature measurements in conjunction with a numerical process model. The quenching stress for HA was measured to be about 10-25 MPa and the residual stress level in HA coatings at room temperature are predicted to lie in the approximate range of 20-40 MPa (tensile). These residual stresses could be reduced in magnitude by maintaining the substrate at a low temperature (possibly below room temperature) during spraying and it may be worthwhile to explore this. Ideally, the HA coating should have low porosity, high cohesive strength, good adhesion to the substrate, a high degree of crystallinity and high chemical purity and phase stability. In practice, such combinations are rather difficult to achieve by just varying the spraying parameters.

  18. Automation of a neutron diffractometer for analysis of residual stress inside complex engineering components

    NASA Astrophysics Data System (ADS)

    Ganguly, S.; James, J. A.; Fitzpatrick, M. E.; Tanguy, A.

    2010-06-01

    Residual stress measurement using neutron diffraction is becoming an increasingly important tool in engineering stress analysis. To this effect, a new generation of dedicated engineering strain instruments are being built at neutron sources, offering considerable improvements in both counting time and spatial resolution. Alongside these improvements, measurements in complex geometry prototype components are increasingly in demand. As a result, there is a strong drive towards integrated sample positioning systems that allow for simplified setup and operating of experiments on components with complex geometries. The present study details work carried out at the ENGIN-X instrument at the UK’s ISIS pulsed neutron source, on measurements in a prototype metal matrix composite (MMC) aircraft wheel, forged from a billet produced through a powder-metallurgy route. The measurement was designed to obtain the macrostress and misfit stresses developed in the matrix and in the reinforcement phase in the wheel during fabrication. The study also demonstrates the use of the SScanSS software for experimental design and implementation, which was developed to complement the advances in the instrumentation of new strain mapping diffractometers. SScanSS simplifies the precise spatial location of the measuring gauge volume inside such complex components.

  19. Enhancement of residual stress by electromagnetic fluctuations: A quasi-linear study

    NASA Astrophysics Data System (ADS)

    Kaang, Helen H.; Jhang, Hogun; Singh, R.; Kim, Juhyung; Kim, S. S.

    2016-05-01

    A study is conducted on the impact of electromagnetic (EM) fluctuations on residual Reynolds stress in the context of the quasi-linear theory. We employ a fluid formulation describing EM ion temperature gradient turbulence. Analyses show that finite plasma β (=plasma thermal energy/magnetic energy) significantly increases the residual stress, potentially leading to the strong enhancement of flow generation in high β plasmas. We identify that this strong increase of residual stress originates from the reinforcement of radial ⟨ k ∥ ⟩ (=spectrally averaged parallel wavenumber) asymmetry due to the deformation of eigenfunctions near a rational surface.

  20. Research on the residual stress of glass ceramic based on rotary ultrasonic drilling

    NASA Astrophysics Data System (ADS)

    Sun, Lipeng; Jin, Yuzhu; Chen, Jianhua

    2016-10-01

    In the process of machining, the glass ceramic is easy to crack and damage, etc. And the residual stress in the machined surface may cause the crack to different extent in the later stage. Some may even affect the performance of the product. The residual stress of rotary ultrasonic drilling and mechanical processing is compared in different machining parameters (spindle speed, feed rate). The effects of processing parameters and methods are researched, in order to reduce the residual stress in the mechanical processing of glass ceramic, and provide guidance for the actual processing.

  1. Microstructural Evolution and Residual Stresses of Air-Plasma Sprayed Thermal Barrier Coatings Under Thermal Exposure

    NASA Astrophysics Data System (ADS)

    Kwon, Jae-Young; Kim, Jae-Hyoun; Lee, Sang-Yeop; Jung, Yeon-Gil; Cho, Hyun; Yi, Dong-Kee; Paik, Ungyu

    Microstructural evolution and fracture behavior of zirconia (ZrO2)-based thermal barrier coatings (TBCs) were investigated under thermal exposure. New ZrO2 granule with 8 wt.% yttria (Y2O3) with a deformed hollow morphology was developed through a spray drying process and employed to prepare TBCs. The thermal exposure tests were conducted at 1210°C with a dwell time of 100 h till 800 h. The residual stress at the interface between top coat and thermally grown oxide (TGO) layer was measured using a nanoindentation technique before and after thermal exposure. Vertical cracks on the top coat were newly formed and interlamellar cracks at the interface were enhanced after the thermal exposure of 800 h. Especially, partial delamination was observed at the interface after the thermal exposure of 800 h in TBC samples tested. The microstructural evolution in the top coat could be defined through load-displacement curves, showing a higher load or a less displacement after the thermal exposure of 800 h. The stress state was strongly dependent on the TGO geometry, resulting in the compressive stresses at the "valleys" or the "troughs," and the tensile stresses at the "crests" or peak areas, in the ranges of -500 to -75 MPa and of +168 to + 24 MPa, respectively. These stress terms incorporated with resintering during thermal exposure affected the mechanical properties such as hardness and elastic modulus of the top coat.

  2. Finite element analysis of residual stress field induced by laser shock peening

    NASA Astrophysics Data System (ADS)

    Nam, Taeksun

    The finite element method is applied to analyze the laser shock peening process (LSP) for thick parts (considered as a semi-infinite half space) and thin parts (finite thickness domain). The technology of LSP is used to enhance mechanical properties such as fatigue life, fretting fatigue life, resistance to stress corrosion cracking and surface hardness. These enhanced material properties are directly related to the magnitude and distribution of the plastic strain and associated residual stresses due to shockwaves induced by LSP. To reduce the process development cost and time, the prediction of residual stress field is very useful to provide a base design guideline for selecting appropriate LSP conditions for evaluation. An axisymmetric Finite Element Analysis (FEA) code, named SHOCKWAVE, is developed in order to complement shortcomings of applying commercial FEA codes at extremely high strain rates (as high as 104 -106/sec). The rate dependent plasticity theory is applied along with the small strain assumption. The solution process consists of an explicit dynamic loading analysis for shock loading stage and a static unloading analysis (implicit) to determine the equilibrium state for the residual stress and plastic strain fields. Some of the highlights explored in this investigation entail: (i) overstress power law models for the rate dependence, (ii) various hardening models, (iii) a second-order accurate implicit algorithm for the plastic consistency condition, (iv) an adaptively expanding domain scheme to trace the stress-free boundary condition in a simple way, (v) a special uniform meshing scheme to avoid the usual assembly process and repeated calculations for the stiffness matrix, (vi) mesh sensitivity study, (vii) comparisons with measured data provided and supported by the LSP Technologies, Inc. The dynamic behavior of Ti-6Al-4V at high strain rates can be investigated by using the split torsional Hopkinson bar experiment and by a longitudinal shock

  3. Residual Stress Relaxation and Stiffness-Confinement Effects in Polymer Films: Characterization by Non-Contact Ellipsometry and Fluorescence Techniques

    NASA Astrophysics Data System (ADS)

    Askar, Shadid; Torkelson, John

    2015-03-01

    The relaxation of residual stresses in spin-coated polymer films is characterized using two optical techniques: ellipsometry and fluorescence. Both techniques show that residual stresses relax over hours at several tens of degrees above the film glass transition temperature (Tg). Ellipsometry shows that thickness can increase or decrease during residual stress relaxation depending on thermal history of the film. However, the presence or relaxation of stresses has no measurable effect on Tg as measured by ellipsometry. We have adapted the well-known sensitivity of the pyrene dye fluorescence spectral shape to local environment polarity in order to characterize stress relaxation and to monitor stiffness-confinement effects. The spectral shape of the pyrene fluorescence spectrum shows similar stress relaxation regardless of whether relaxation is accompanied by increases or decreases in film thickness. Fluorescence also indicates that single-layer polystyrene films supported on silica stiffen with decreasing nanoscale thickness. For the first time, stiffness gradients as a function of distance from interfaces are demonstrated using pyrene label fluorescence in conjunction with multilayer films.

  4. Birefringence and residual stress induced by CO2 laser mitigation of damage growth in fused silica

    NASA Astrophysics Data System (ADS)

    Gallais, L.; Cormont, P.; Rullier, J. L.

    2009-10-01

    We investigate the residual stress field created near mitigated sites and its influence on the efficiency on the CO2 laser mitigation of damage growth process. A numerical model of CO2 laser interaction with fused silica is developed that take into account laser energy absorption, heat transfer, thermally-induced stress and birefringence. Specific photoelastic methods are developed to characterize the residual stress near mitigated sites in fused silica samples. The stress distribution and quantitative values of stress levels are obtained for sites treated with the CO2 laser in various conditions of energy deposition (beam size, pulse duration, incident power). The results obtained also show that the presence of birefringence/residual stress around the mitigated sites has a critical effect on their laser damage resistance.

  5. Residual stress in laser welded dissimilar steel tube-to-tube joints

    SciTech Connect

    Sun, Zheng . Lab. of Production Engineering)

    1993-09-01

    Austenitic-ferritic dissimilar steel joints are widely used in power generation systems. Their utilization has proved to be efficient in terms of satisfactory properties and the economics. These types of joints have usually been produced using conventional welding processes, such as tungsten inert gas (TIG) welding. With the rapid development of high power lasers, laser welding has received considerable attention. Laser welding offers many advantages over conventional welding processes, e.g. low heat input, small heat-affected zone (HAZ), small distortion, and welding in an exact and reproducible manner. Residual stress distribution in laser welds may also differ from those made by conventional welding processes due to its special features. Residual stress, particularly tensile residual stress in the weld, can be very important factor in controlling the quality and service life of the welded structure. The formation of tensile residual stress in the weld may result in the initiation of fatigue cracking, stress corrosion cracking or other types of fractures. It is useful, therefore, to understand the distribution of residual stress in austenitic-ferritic laser welds, and thus evaluate the quality of the joints. Although residual stress distribution in the welded joints has been extensively investigated, little data are available for the residual stress distribution in laser welds. The aim of the work was to examine residual stress distribution along laser welds of dissimilar steel tube-to-tube joints, which were made by both autogeneous welding and welding with filler wire. The results were also compared with the joints made by plasma arc and TIG welding.

  6. PESTICIDE SURFACE RESIDUE MEASUREMENTS BY A PRESS SAMPLER

    EPA Science Inventory

    Pesticides on household surfaces are a source of exposure to children. Accurate measurements of residues on surfaces are needed to determine amounts available for transfer to foods and other objects handled or eaten by a child. Wiping the surface with a solvent has been the acc...

  7. PESTICIDE SURFACE RESIDUE MEASUREMENTS BY A PRESS SAMPLER

    EPA Science Inventory

    Pesticides on household surfaces are a source of exposure to children. Accurate measurements of residues on surfaces are needed to determine amounts available for transfer to foods and other objects handled or eaten by a child. Wiping the surface with a solvent has been the acc...

  8. Solvent residue content measured by light scattering technique

    NASA Technical Reports Server (NTRS)

    Salkowski, M. J.; Werle, D. K.

    1966-01-01

    Photometric analyzer measures NVR /nonvolatile residue/ in trichloroethylene and other organic solvents. The analyzer converts the liquid solvent to aerosol and passes it between an optically focused light beam and a photodetector that is connected to standard amplifying and readout equipment.

  9. Residual stress analysis of an aircraft landing gear part using neutron diffraction

    NASA Astrophysics Data System (ADS)

    Shin, Eunjoo; Seong, Baek Seok; Sim, Cheul Muu

    2013-07-01

    The residual stress of a landing gear part of a fighter jet that has a frequent practice of takeoff and landing was evaluated for the safety. The sample was a cylindrical steel bar with a 22.2 mm diameter and 55 mm length used to fix the main landing gear to the aircraft body. For a deep measurement up to 6 mm, we used a neutron beam. From the measurements, the tensile and compressive strain in the axial direction were observed around one side of the pin hole which was across the steel bar vertically with an 8 mm diameter. The strain distribution along the length of the bar presented a similar tendency through the thickness and a larger value on the surface. The maximum value of the residual stress around the pin hole was about 100 MPa. However, there was no strain on the opposite side of the pin hole. From the results, it may be surmised that the steel bar received a steady force in one direction around the pin hole, however the force was weak and affected a small limited area and thus not influence on the steel bar on the whole.

  10. Measurement of residual strains in boron-epoxy and glass-epoxy laminates

    NASA Technical Reports Server (NTRS)

    Daniel, I. M.; Liber, T.; Chamis, C. C.

    1975-01-01

    Embedded-strain-gage techniques were developed and used for measuring strains in composite angle-ply laminates during curing and thermal cycling. The specimens were 2.54 by 22.9 cm eight-ply boron-epoxy and S-glass-epoxy laminates. Unidirectional specimens were used for control purposes. Strain readings were corrected for the purely thermal output of the gages obtained from an instrument quartz reference specimen. The strains measured during the cooling part of the curing cycle were in agreement with those recorded during subsequent thermal cycling, indicating that residual stresses induced during curing are primarily caused by differential thermal expansions of the various plies. Restraint strains were computed for the 0-deg and 45-deg plies of the angle-ply laminates tested, and the residual stresses obtained using the anisotropic constitutive relations and taking into account the temperature dependence of stiffnesses and strains.

  11. Infrared Spectroscopy of Explosives Residues: Measurement Techniques and Spectral Analysis

    SciTech Connect

    Phillips, Mark C.; Bernacki, Bruce E.

    2015-03-11

    Infrared laser spectroscopy of explosives is a promising technique for standoff and non-contact detection applications. However, the interpretation of spectra obtained in typical standoff measurement configurations presents numerous challenges. Understanding the variability in observed spectra from explosives residues and particles is crucial for design and implementation of detection algorithms with high detection confidence and low false alarm probability. We discuss a series of infrared spectroscopic techniques applied toward measuring and interpreting the reflectance spectra obtained from explosives particles and residues. These techniques utilize the high spectral radiance, broad tuning range, rapid wavelength tuning, high scan reproducibility, and low noise of an external cavity quantum cascade laser (ECQCL) system developed at Pacific Northwest National Laboratory. The ECQCL source permits measurements in configurations which would be either impractical or overly time-consuming with broadband, incoherent infrared sources, and enables a combination of rapid measurement speed and high detection sensitivity. The spectroscopic methods employed include standoff hyperspectral reflectance imaging, quantitative measurements of diffuse reflectance spectra, reflection-absorption infrared spectroscopy, microscopic imaging and spectroscopy, and nano-scale imaging and spectroscopy. Measurements of explosives particles and residues reveal important factors affecting observed reflectance spectra, including measurement geometry, substrate on which the explosives are deposited, and morphological effects such as particle shape, size, orientation, and crystal structure.

  12. Effect of texture and grain size on the residual stress of nanocrystalline thin films

    NASA Astrophysics Data System (ADS)

    Cao, Lei; Sengupta, Arkaprabha; Pantuso, Daniel; Koslowski, Marisol

    2017-10-01

    Residual stresses develop in thin film interconnects mainly as a result of deposition conditions and multiple thermal loading cycles during the manufacturing flow. Understanding the relation between the distribution of residual stress and the interconnect microstructure is of key importance to manage the nucleation and growth of defects that can lead to failure under reliability testing and use conditions. Dislocation dynamics simulations are performed in nanocrystalline copper subjected to cyclic loading to quantify the distribution of residual stresses as a function of grain misorientation and grain size distribution. The outcomes of this work help to evaluate the effect of microstructure in thin films failure by identifying potential voiding sites. Furthermore, the simulations show how dislocation structures are influenced by texture and grain size distribution that affect the residual stress. For example, when dislocation loops reach the opposite grain boundary during loading, these dislocations remain locked during unloading.

  13. On residual stresses and homeostasis: an elastic theory of functional adaptation in living matter

    PubMed Central

    Ciarletta, P.; Destrade, M.; Gower, A. L.

    2016-01-01

    Living matter can functionally adapt to external physical factors by developing internal tensions, easily revealed by cutting experiments. Nonetheless, residual stresses intrinsically have a complex spatial distribution, and destructive techniques cannot be used to identify a natural stress-free configuration. This work proposes a novel elastic theory of pre-stressed materials. Imposing physical compatibility and symmetry arguments, we define a new class of free energies explicitly depending on the internal stresses. This theory is finally applied to the study of arterial remodelling, proving its potential for the non-destructive determination of the residual tensions within biological materials. PMID:27113413

  14. On residual stresses and homeostasis: an elastic theory of functional adaptation in living matter

    NASA Astrophysics Data System (ADS)

    Ciarletta, P.; Destrade, M.; Gower, A. L.

    2016-04-01

    Living matter can functionally adapt to external physical factors by developing internal tensions, easily revealed by cutting experiments. Nonetheless, residual stresses intrinsically have a complex spatial distribution, and destructive techniques cannot be used to identify a natural stress-free configuration. This work proposes a novel elastic theory of pre-stressed materials. Imposing physical compatibility and symmetry arguments, we define a new class of free energies explicitly depending on the internal stresses. This theory is finally applied to the study of arterial remodelling, proving its potential for the non-destructive determination of the residual tensions within biological materials.

  15. The effect of fibre pre-tension on residual stresses in fibre composites

    NASA Astrophysics Data System (ADS)

    Kim, Jang-Kyo; Mai, Yiu-Wing; Cotterell, Brian

    The residual stresses resulting from fiber pretension is estimated from a simple model. The principal effect of fiber pretension is to improve the mechanical bonding at the interface which promotes frictional resistance during fiber pull-out. The fiber pull-out stresses are approximately estimated by superimposing the additional residual clamping stress at the interface due to fiber pretension. Comparison of the theory with experimental results on steel wire-epoxy matrix model composites shows a reasonable agreement, particularly for the frictional pull-out stress after complete debonding.

  16. Neutron and x-ray scattering studies of the metallurgical condition and residual stresses in Weldalite welds

    SciTech Connect

    Spooner, S.; Pardue, E.B.S.

    1995-12-31

    Weldalite is a lithium-containing aluminum alloy which is being considered for aerospace applications because its favorable strength-to-weight ratio. Successful welding of this alloy depends on the control of the metallurgical condition and residual stresses in the heat affected zone. Neutron and x-ray scattering methods of residual stress measurement were applied to plasma arc welds made in aluminum-lithium alloy test panels as part of an evaluation of materials for use in welded structures. In the course of these studies discrepancies between x-ray and neutron results from the heat affected zone (HAZ) of the weld were found. Texture changes and recovery from the cold work, indicated in peak widths, were found in the HAZ as well. The consideration of x-ray and neutron results leads to the conclusion that there is a change in solute composition which modifies the d-spacings in the HAZ which affects the neutron diffraction determination of residual stresses. The composition changes give the appearance of significant compressive strains in the HAZ. This effect and sharp gradients in the texture give severe anomalies in the neutron measurement of residual stress. The use of combined x-ray and neutron techniques and the solution to the minimizing of the neutron diffraction anomalies are discussed.

  17. Measurement and control for mechanical compressive stress

    NASA Astrophysics Data System (ADS)

    Li, Qing; Ye, Guang; Pan, Lan; Wu, Xiushan

    2001-12-01

    At present, the indirect method is applied to measuring and controlling mechanical compressive stress, which is the measurement and control of rotating torque of screw with torque transducer during screw revolving. Because the friction coefficient between every screw-cap and washer, of screw-thread is different, the compressive stress of every screw may is different when the machinery is equipped. Therefore, the accurate measurement and control of mechanical compressive stress is realized by the direct measurement of mechanical compressive stress. The author introduces the research of contrast between compressive stress and rotating torque in the paper. The structure and work principle of a special washer type transducer is discussed emphatically. The special instrument cooperates with the washer type transducer for measuring and controlling mechanical compressive stress. The control tactics based on the rate of compressive stress is put to realize accurate control of mechanical compressive stress.

  18. Residual stresses in oxide scale formed on Fe-17Cr stainless steel

    NASA Astrophysics Data System (ADS)

    Li, Ning; Xiao, Ji; Prud'homme, Nathalie; Chen, Zhe; Ji, Vincent

    2014-10-01

    The purpose of this work was to investigate residual stresses in the oxide scale formed on ferritic stainless steel, which is proposed to be used as interconnector in the planar solid oxide fuel cells (SOFCs). The oxidation of the alloy has been conducted at 700 °C, 800 °C and 900 °C for 12-96 h by thermal gravimetric analysis (TGA) system. The oxide surface morphology, cross-section microstructure and the chemical composition of the oxide scale were studied after oxidation, and the residual stresses distribution of the oxide scale were determined at room temperature. It has been found that the oxide scale composed of an inner Cr2O3 layer and an outer Mn1.5Cr1.5O4 spinel layer, the residual stresses in both oxide layers are compressive and the growth stresses plays an important role. The competition of the stresses generation and relaxation during oxidation and cooling affects the residual stresses level. The evolution of residual stresses in the two layers is different according to the oxidation temperature, and the stresses in the two layers are interactional.

  19. Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    McGrann, Roy T. R.; Rybicki, Edmund F.; Shadley, John R.; Brindley, William J.

    1997-01-01

    To improve gas turbine and diesel engine performance using thermal barrier coatings (TBC's) requires an understanding of the factors that influence the in-service behavior of thermal barrier coatings. One of the many factors related to coating performance is the state of stress in the coating. The total stress state is composed of the stresses due to the in-service loading history and the residual stresses. Residual stresses have been shown to affect TBC life, the bond strength of thermal spray coatings, and the fatigue life of tungsten carbide coatings. Residual stresses are first introduced in TBC's by the spraying process due to elevated temperatures during processing and the difference in coefficients of thermal expansion of the top coat, bond coat, and substrate. Later, the residual stresses can be changed by the in-service temperature history due to a number of time and temperature dependent mechanisms, such as oxidation, creep, and sintering. Silica content has also been shown to affect sintering and the cyclic life of thermal barrier coatings. Thus, it is important to understand how the spraying process, the in-service thermal cycles, and the silica content can create and alter residual stresses in thermal barrier coatings.

  20. Mode shape identification using residues of measured offshore structure data

    NASA Astrophysics Data System (ADS)

    Wang, Chao; Liu, Fushun; Lu, Hongchao

    2017-04-01

    Compared to traditional mode shape identification methods such as eigensystem realization algorithm (ERA), this article proposes a mode shape identification method based on estimated residues of measured data and the theoretical relationship between the estimated residues and the mode shapes from the state space model is obtained by defining a coefficient matrix. A mass-spring model with five degrees of freedom (DOFs) is utilized to demonstrate the approach. The numerical results indicate that the estimated residues are the mode shapes of structures, but with a coefficient matrix to maintain consistency with the mode shapes from the ERA. Using MATLAB a complicated numerical jacket platform is built to further study the proposed method. The results show that mode shapes consistent with those from the ERA could be obtained by taking the defined coefficient matrix into account, which is also demonstrated by a physical beam model that was built at Ocean University of China.

  1. Influence and Modeling of Residual Stresses in Thick Walled Pressure Vessels with Through Holes

    DTIC Science & Technology

    2012-02-28

    Technical Report ARWSB-TR-12003 INFLUENCE AND MODELING OF RESIDUAL STRESSES IN THICK WALLED PRESSURE VESSELS WITH...DATE (DD-MM-YYYY) 28/02/2012 2. REPORT TYPE Technical Report 3. DATES COVERED (From - To) 4. TITLE AND SUBTITLE Influence and Modeling of...Residual Stresses in Thick Walled Pressure Vessels with Through Holes 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT

  2. Assessment of Residual Stresses in 3013 Inner and Outer Containers and Teardrop Samples

    SciTech Connect

    Stroud, Mary Ann; Prime, Michael Bruce; Veirs, Douglas Kirk; Berg, John M.; Clausen, Bjorn; Worl, Laura Ann; DeWald, Adrian T.

    2015-12-08

    This report is an assessment performed by LANL that examines packaging for plutonium-bearing materials and the resilience of its design. This report discusses residual stresses in the 3013 outer, the SRS/Hanford and RFETS/LLNL inner containers, and teardrop samples used in studies to assess the potential for SCC in 3013 containers. Residual tensile stresses in the heat affected zones of the closure welds are of particular concern.

  3. Relief of Residual Stress in Streamline Tie Rods by Heat Treatment

    DTIC Science & Technology

    1941-11-01

    major axis, pounds ~er square inch ~ --— modulus of elasticity (3 ‘X 107 lb/eq. in.) c1 “distance f,ron saw cut “to,neutral axis of seg- ment - 0.42...the ends of specimens with a saw cuti . The residual stress was then calculated.b~ diviaing by the ratio of partial,to mean residual stress displayed by

  4. Effect of Plastic Pre-straining on Residual Stress and Composition Profiles in Low-Temperature Surface-Hardened Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Bottoli, Federico; Christiansen, Thomas L.; Winther, Grethe; Somers, Marcel A. J.

    2016-08-01

    The present work deals with the evaluation of the residual stress profiles in expanded austenite by applying grazing incidence X-ray diffraction (GI-XRD) combined with successive sublayer removal. Annealed and deformed ( ɛ eq=0.5) samples of stable stainless steel EN 1.4369 were nitrided or nitrocarburized. The residual stress profiles resulting from the thermochemical low-temperature surface treatment were measured. The results indicate high-residual compressive stresses of several GPa's in the nitrided region, while lower-compressive stresses are produced in the carburized case. Plastic deformation in the steel prior to thermochemical treatment has a hardly measurable influence on the nitrogen-rich zone, while it has a measurable effect on the stresses and depth of the carbon-rich zone.

  5. Verification of residual stresses in flash-butt-weld rails using neutron diffraction

    NASA Astrophysics Data System (ADS)

    Tawfik, David; Kirstein, Oliver; Mutton, Peter John; Chiu, Wing Kong

    2006-11-01

    Residual stresses developed during flash-butt welding may play a crucial role in prolonging the fatigue life of the welded tracks under service loading conditions. The finished welds typically exhibit high levels of tensile residual stresses in the web region of the weld. Moreover, the surface condition of the web may contain shear drag or other defects resulting from the shearing process which may lead to the initiation and propagation of fatigue cracks in a horizontal split web failure mode under high axle loads. However, a comprehensive understanding into the residual stress behaviour throughout the complex weld geometry remains unclear and is considered necessary to establish the correct localised post-weld heat treatment modifications intended to lower tensile residual stresses. This investigation used the neutron diffraction technique to analyse residual stresses in an AS60 flash-butt-welded rail cooled under normal operating conditions. The findings will ultimately contribute to developing modifications to the flash-butt-welding procedure to lower tensile residual stresses which may then improve rail performance under high axle load.

  6. Residual stress characteristics in a non-circular drawing sequence of pearlitic steel wire

    NASA Astrophysics Data System (ADS)

    Baek, Hyun Moo; Hwang, Sun Kwang; Son, Il-Heon; Im, Yong-Taek

    2016-11-01

    In this paper, characteristics of residual stress in pearlitic steel wire drawn by a non-circular drawing (NCD) sequence with two processing routes, NCDA and NCDB, were experimentally and numerically investigated up to the 12th pass in comparison with conventional wire drawing (WD). For experimental investigation of the axial residual stress at the surface of the drawn wire, destructive (deflection) and non-destructive methods were employed. According to the experimental results, axial surface residual stress of the drawn wire by the NCD sequence was lower and more homogeneous compared to the conventional WD. Based on the elasto-plastic numerical simulation results from the surface to the center of the drawn wire using a commercial DEFORM-3D, an empirical relationship between residual stress and reduction of area was determined to predict the residual stress evolution in the multi-pass WD, NCDA, and NCDB, in that order. From the results of this investigation, it can be construed that the NCD sequence, especially the NCDB, might be helpful in improving the residual stress characteristics of pearlitic steel wire to improve its mechanical behavior and service life.

  7. INTERFACE RESIDUAL STRESSES IN DENTAL ZIRCONIA USING LAUE MICRO-DIFFRACTION

    SciTech Connect

    Bale, H. A.; Tamura, N.; Coelho, P.G.; Hanan, J. C.

    2009-01-01

    Due to their aesthetic value and high compressive strength, dentists have recently employed ceramics for restoration materials. Among the ceramic materials, zirconia provides high toughness and crack resistant characteristics. Residual stresses develop in processing due to factors including grain anisotropy and thermal coefficient mismatch. In the present study, polychromatic X-ray (Laue) micro-diffraction provided grain orientation and residual stresses on a clinically relevant zirconia model ceramic disk. A 0.5 mm x 0.024 mm region on zirconia was examined on a 500 nm scale for residual stresses using a focused poly-chromatic synchrotron X-ray beam. Large stresses ranging from - to + 1GPa were observed at some grains. On average, the method suggests a relatively small compressive stress at the surface between 47 and 75 MPa depending on direction.

  8. Influence of Material Model on Prediction Accuracy of Welding Residual Stress in an Austenitic Stainless Steel Multi-pass Butt-Welded Joint

    NASA Astrophysics Data System (ADS)

    Deng, Dean; Zhang, Chaohua; Pu, Xiaowei; Liang, Wei

    2017-03-01

    Both experimental method and numerical simulation technology were employed to investigate welding residual stress distribution in a SUS304 steel multi-pass butt-welded joint in the current study. The main objective is to clarify the influence of strain hardening model and the yield strength of weld metal on prediction accuracy of welding residual stress. In the experiment, a SUS304 steel butt-welded joint with 17 passes was fabricated, and the welding residual stresses on both the upper and bottom surfaces of the middle cross section were measured. Meanwhile, based on ABAQUS Code, an advanced computational approach considering different plastic models as well as annealing effect was developed to simulate welding residual stress. In the simulations, the perfect plastic model, the isotropic strain hardening model, the kinematic strain hardening model and the mixed isotropic-kinematic strain hardening model were employed to calculate the welding residual stress distributions in the multi-pass butt-welded joint. In all plastic models with the consideration of strain hardening, the annealing effect was also taken into account. In addition, the influence of the yield strength of weld metal on the simulation result of residual stress was also investigated numerically. The conclusions drawn by this work will be helpful in predicting welding residual stresses of austenitic stainless steel welded structures used in nuclear power plants.

  9. Influence of Material Model on Prediction Accuracy of Welding Residual Stress in an Austenitic Stainless Steel Multi-pass Butt-Welded Joint

    NASA Astrophysics Data System (ADS)

    Deng, Dean; Zhang, Chaohua; Pu, Xiaowei; Liang, Wei

    2017-04-01

    Both experimental method and numerical simulation technology were employed to investigate welding residual stress distribution in a SUS304 steel multi-pass butt-welded joint in the current study. The main objective is to clarify the influence of strain hardening model and the yield strength of weld metal on prediction accuracy of welding residual stress. In the experiment, a SUS304 steel butt-welded joint with 17 passes was fabricated, and the welding residual stresses on both the upper and bottom surfaces of the middle cross section were measured. Meanwhile, based on ABAQUS Code, an advanced computational approach considering different plastic models as well as annealing effect was developed to simulate welding residual stress. In the simulations, the perfect plastic model, the isotropic strain hardening model, the kinematic strain hardening model and the mixed isotropic-kinematic strain hardening model were employed to calculate the welding residual stress distributions in the multi-pass butt-welded joint. In all plastic models with the consideration of strain hardening, the annealing effect was also taken into account. In addition, the influence of the yield strength of weld metal on the simulation result of residual stress was also investigated numerically. The conclusions drawn by this work will be helpful in predicting welding residual stresses of austenitic stainless steel welded structures used in nuclear power plants.

  10. Integrated experimental and computational approach for residual stress investigation near through-silicon vias

    NASA Astrophysics Data System (ADS)

    Deluca, Marco; Hammer, René; Keckes, Jozef; Kraft, Jochen; Schrank, Franz; Todt, Juraj; Robach, Odile; Micha, Jean-Sébastien; Defregger, Stefan

    2016-11-01

    The performance of three-dimensional integrated circuits is decisively influenced by the thermo-mechanical behavior of through-silicon vias (TSVs), which are subjected to stresses formed during fabrication process as well as cyclic operation as a result of coefficients of thermal expansion (CTEs) mismatch between the silicon substrate, passivation layers, and metallic conduction paths. In this work, we adopted an integrated approach combining micro-Raman, wafer curvature experiments, and finite element (FE) modeling to study the triaxial residual stresses in silicon in the vicinity of W-coated hollow TSVs. A comparison of the experimental and calculated Raman shifts from a TSV cross section allowed a validation of the FE model, which was then extended to a non-sliced TSV. In the next step, the calculated bulk strains were compared with the ones measured using synchrotron X-ray micro-diffraction in order to specifically assess the stress decrease in Si as a function of the distance from the TSV wall within ˜25 μm. The experimental verification of the FE model demonstrates the importance of combined experimental-computational approaches to study stresses in micro-scale devices with complex morphology.

  11. Effects of interface edge configuration on residual stress in the bonded structures for a divertor application

    NASA Astrophysics Data System (ADS)

    Kitamura, K.; Nagata, K.; Shibui, M.; Tachikawa, N.; Araki, M.

    1998-10-01

    Residual stresses in the interface region, that developed at the cool down during the brazing, were evaluated for several bonded structures to assess the mechanical strength of the bonded interface, using thermoelasto-plastic stress analysis. Normal stress components of the residual stresses around the interface edge of graphite-copper (C-Cu) bonded structures were compared for three types of bonded features such as flat-type, monoblock-type and saddle-type. The saddle-type structure was found to be favorable for its relatively low residual stress, easy fabrication accuracy on bonded interface and armor replacement. Residual stresses around the interface edge in three armor materials/copper bonded structures for a divertor plate were also examined for the C-Cu, tungsten-copper (W-Cu) and molybdenum alloy-copper (TZM-Cu), varying the interface wedge angle from 45° to 135°. An optimal bonded configuration for the least value of residual stress was found to have a wedge angle of 45° for the C-Cu, and 135° for both the W-Cu and TZM-Cu bonded ones.

  12. Analysis of Residual Stresses in Laser-Shock-Peened and Shot-Peened Marine Steel Welds

    NASA Astrophysics Data System (ADS)

    Ahmad, Bilal; Fitzpatrick, Michael E.

    2017-02-01

    Laser peening is now the preferred method of surface treatment in many applications. The magnitude and depth of the compressive residual stress induced by laser peening can be influenced strongly by the number of peen layers (the number of laser hits at each point) and by processing conditions including the use of a protective ablative layer. In this study, residual stresses have been characterized in laser and shot-peened marine butt welds with a particular focus at the fatigue crack initiation location at the weld toe. X-ray diffraction, synchrotron X-ray diffraction, incremental center-hole drilling, and the contour method were used for determination of residual stress. Results showed that the use of ablative tape increased the surface compressive stress, and the depth of compressive stress increased with an increase in number of peening layers. A key result is that variation of residual stress profile across laser peen spots was seen, and the residual stress magnitude varies between the center and edges of the spots.

  13. Residual stress and Raman spectra of laser deposited highly-tetrahedral-coordinated-amorphous-carbon films

    SciTech Connect

    Friedmann, T.A.; Siegal, M.P.; Tallant, D.R.; Simpson, R.L.; Dominguez, F.

    1994-05-01

    We are studying carbon thin films by using a pulsed excimer laser to ablate pyrolytic graphite targets to form highly tetrahedral coordinated amorphous carbon ({alpha}t-C) films. These films have been grown on room temperature p-type Si (100) substrates without the intentional incorporation of hydrogen. In order to understand and optimize the growth of {alpha}t-C films, parametric studies of the growth parameters have been performed. We have also introduced various background gases (H{sub 2}, N{sub 2} and Ar) and varied the background gas pressure during deposition. The residual compressive stress levels in the films have been measured and correlated to changes in the Raman spectra of the {alpha}t-C band near 1565 cm{sup {minus}1}. The residual compressive stress falls with gas pressure, indicating a decreasing atomic sp{sup 3}-bonded carbon fraction. We find that reactive gases such as hydrogen and nitrogen significantly alter the Raman spectra at higher pressures. These effects are due to a combination of chemical incorporation of nitrogen and hydrogen into the film as well as collisional cooling of the ablation plume. In contrast, films grown in non-reactive Ar background gases show much less dramatic changes in the Raman spectra at similar pressures.

  14. Effect of Laser Shock Peening on surface properties and residual stress of Al6061-T6

    NASA Astrophysics Data System (ADS)

    Salimianrizi, A.; Foroozmehr, E.; Badrossamay, M.; Farrokhpour, H.

    2016-02-01

    The purpose of this study is to investigate the effects of Laser Shock Peening (LSP) on Al 6061-T6. The confined LSP regime using Nd: YAG laser with 1200 mJ of energy per pulse and 8 ns of pulse width were applied. The treated specimens were evaluated by means of surface integrity with optical microscopy, scanning electron microscope, microhardness, surface roughness and induced residual stress using an X-ray diffraction method. Results showed that by the use of LSP, compressive residual stress could effectively be induced on the surface of treated material. It was also revealed that the hardened depth of the material, up to a maximum depth of 1875 μm, could be achieved due to work hardening and grain refinement. In addition, surface roughness measurements showed that the LSP could deteriorate surface quality depending on the LSP parameters. The influences of beam overlap rates, number of laser shots and scanning pattern on microhardness as well as surface roughness are discussed.

  15. Physically-based constitutive modelling of residual stress development in welding of aluminium alloy 2024

    SciTech Connect

    Preston, R.V.; Shercliff, H.R. . E-mail: hrs@eng.cam.ac.uk; Withers, P.J.; Smith, S.

    2004-10-04

    A finite element model has been developed to predict the evolution of residual stress and distortion which takes into account the history-dependence of the yield stress-temperature response of heat-treatable aluminium alloys during welding. The model was applied to TIG welding of 2024-T3 aluminium alloy, and the residual strain predictions validated using high resolution X-ray synchrotron diffraction. The goal was to capture the influence of the permanent evolution of the microstructure during the thermal cycle with a straightforward numerical procedure, while retaining a sound physical basis. Hardness and resistivity measurements after isothermal hold-and-quench experiments were used to identify salient temperatures for zero, partial and full dissolution of the initial hardening precipitates, and the extent of softening - both immediately after welding, and after natural ageing. Based on these data, a numerical procedure for weld modelling was proposed for tracking the different yield responses during heating and cooling based on the peak temperature reached locally. This history-dependent model was superior to a conventional model in predicting the peak tensile strains, but otherwise the effect of temperature history was weak for 2024-T3. Predictions of the hardness profile immediately after welding compared with the post-weld naturally aged hardness provided insight into the competition between dissolution and coarsening of the precipitates in the heat-affected zone.

  16. Residual stress in Ta2O5-SiO2 composite thin-film rugate filters prepared by radio frequency ion-beam sputtering.

    PubMed

    Tang, Chien-Jen; Jaing, Cheng-Chung; Lee, Kuan-Shiang; Lee, Cheng-Chung

    2008-05-01

    Ta-Si oxide composite thin-film rugate filters were prepared by radio frequency ion-beam sputtering and their residual stress and substrate deflections were measured. The residual stress and substrate deflection of these composite film rugate filters were less than that of notch filters made from a series of discrete quarter-wave layers with alternate high and low indices because of the smooth modulation of composition and no interface structure of the rugate filter.

  17. Effect of injection-molding-induced residual stress on microchannel deformation irregularity during thermal bonding

    NASA Astrophysics Data System (ADS)

    Yu, H.; Tor, S. B.; Loh, N. H.; Asundi, A. K.

    2013-01-01

    Micro injection molding offers a promising approach to rapidly produce thermoplastic microfluidic substrates in large volumes. Many research works have been focused on the replication fidelity of microstructures by injection molding. However, there has not been any investigation on the effect of molded-in residual stress on microchannel deformation during the subsequent thermal bonding process. These effects could be important, because the residual stress developed due to anisotropic polymer flow orientation and inhomogeneous cooling may lead to abnormal microchannel distortion. In the direct thermal bonding process, asymmetric cross-sectional distortion was observed in well-formed microchannels aligned perpendicular to the polymer melt injection direction. This asymmetric distortion is attributed to the residual stress introduced into the substrates during molding, particularly in the surface region where microchannels are molded. Design of experiment on injection molding was carried out to reduce the residual stress in order to achieve the lowest microchannel deformation irregularity, which is a new term defined in this study. The direct thermal bonding was utilized as a feasible non-destructive indirectly quantitative method to evaluate the effect of residual stress around microchannel regarding deformation irregularity. The dominant molding parameters with positive effects were found to be melt temperature, mold temperature as well as cooling time after packing. The