Sample records for residual stress effects

  1. 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.

  2. Effectiveness of stress release geometries on reducing residual stress in electroforming metal microstructure

    NASA Astrophysics Data System (ADS)

    Song, Chang; Du, Liqun; Zhao, Wenjun; Zhu, Heqing; Zhao, Wen; Wang, Weitai

    2018-04-01

    Micro electroforming, as a mature micromachining technology, is widely used to fabricate metal microdevices in micro electro mechanical systems (MEMS). However, large residual stress in the local positions of the micro electroforming layer often leads to non-uniform residual stress distributions, dimension accuracy defects and reliability issues during fabrication of the metal microdevice. To solve this problem, a novel design method of presetting stress release geometries in the topological structure of the metal microstructure is proposed in this paper. First, the effect of stress release geometries (circular shape, annular groove shape and rivet shape) on the residual stress in the metal microstructure was investigated by finite element modeling (FEM) analysis. Two evaluation parameters, stress concentration factor K T and stress non-uniformity factor δ were calculated. The simulation results show that presetting stress release geometries can effectively reduce and homogenize the residual stress in the metal microstructures were measured metal microstructure. By combined use with stress release geometries of annular groove shape and rivet shape, the stress concentration factor K T and the stress non-uniformity factor δ both decreased at a maximum of 49% and 53%, respectively. Meanwhile, the average residual stress σ avg decreased at a maximum of 20% from  -292.4 MPa to  -232.6 MPa. Then, micro electroforming experiments were carried out corresponding to the simulation models. The residual stresses in the metal microstructures were measured by micro Raman spectroscopy (MRS) method. The results of the experiment proved that the stress non-uniformity factor δ and the average residual stress σ avg also decreased at a maximum with the combination use of annular groove shape and rivet shape stress release geometries, which is in agreement with the results of FEM analysis. The stress non-uniformity factor δ has a maximum decrease of 49% and the

  3. Effect of Applied Stress and Temperature on Residual Stresses Induced by Peening Surface Treatments in Alloy 600

    NASA Astrophysics Data System (ADS)

    Telang, A.; Gnäupel-Herold, T.; Gill, A.; Vasudevan, V. K.

    2018-04-01

    In this study, the effects of applied tensile stress and temperature on laser shock peening (LSP) and cavitation shotless peening (CSP)-induced compressive residual stresses were investigated using neutron and x-ray diffraction. Residual stresses on the surface, measured in situ, were lower than the applied stress in LSP- and CSP-treated Alloy 600 samples (2 mm thick). The residual stress averaged over the volume was similar to the applied stress. Compressive residual stresses on the surface and balancing tensile stresses in the interior relax differently due to hardening induced by LSP. Ex situ residual stress measurements, using XRD, show that residual stresses relaxed as the applied stress exceeded the yield strength of the LSP- and CSP-treated Alloy 600. Compressive residual stresses induced by CSP and LSP decreased by 15-25% in magnitude, respectively, on exposure to 250-450 °C for more than 500 h with 10-11% of relaxation occurring in the first few hours. Further, 80% of the compressive residual stresses induced by LSP and CSP treatments in Alloy 600 were retained even after long-term aging at 350 °C for 2400 h.

  4. Effects of weld residual stresses on crack-opening area analysis of pipes for LBB applications

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    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 amore » 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.« less

  5. 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.

  6. Effects of wear and service conditions on residual stresses in commuter car wheels

    DOT National Transportation Integrated Search

    2004-09-01

    This paper illustrates application of the shakedown residual stress estimation technique to : assess the effects of service conditions on wheel residual stresses. The examples described provide the : technical details on how the technique is practica...

  7. 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.

  8. 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.

  9. 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.

  10. Effect of the Leveling Conditions on Residual Stress Evolution of Hot Rolled High Strength Steels for Cold Forming

    NASA Astrophysics Data System (ADS)

    Park, Keecheol; Oh, Kyungsuk

    2017-09-01

    In order to investigate the effect of leveling conditions on residual stress evolution during the leveling process of hot rolled high strength steels, the in-plane residual stresses of sheet processed under controlled conditions at skin-pass mill and levelers were measured by cutting method. The residual stress was localized near the edge of sheet. As the thickness of sheet was increased, the residual stress occurred region was expanded. The magnitude of residual stress within the sheet was reduced as increasing the deformation occurred during the leveling process. But the residual stress itself was not removed completely. The magnitude of camber occurred at cut plate was able to be predicted by the residual stress distribution. A numerical algorithm was developed for analysing the effect of leveling conditions on residual stress. It was able to implement the effect of plastic deformation in leveling, tension, work roll bending, and initial state of sheet (residual stress and curl distribution). The validity of simulated results was verified from comparison with the experimentally measured residual stress and curl in a sheet.

  11. Effects of service conditions on the as-manufactured residual stress distribution in commuter car wheels

    DOT National Transportation Integrated Search

    2001-09-01

    The effects of simulated service conditions on the as-manufactured residual stress : distribution in commuter car wheels are investigated. The residual stresses, those : stresses which remain after all applied loads are removed, can encourage the for...

  12. 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.

  13. Effect of residual stress on modal patterns of MEMS vibratory gyroscope

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Dutta, Shankar, E-mail: shankardutta77@gmail.com; Panchal, Abha; Kumar, Manoj

    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.

  14. Longitudinal residual stresses in boron fibers

    NASA Technical Reports Server (NTRS)

    Behrendt, D. R.

    1976-01-01

    A method of measuring the longitudinal residual stress distribution in boron fibers is presented. The residual stresses in commercial CVD boron on tungsten fibers of 102, 142, and 203 microns (4, 5.6, and 8 mil) diameters were determined. Results for the three sizes show a compressive stress at the surface 800 to -1400 MN/sq m 120 to -200 ksi), changing monotonically to a region of tensile stress within the boron. At approximately 25 percent of the original radius, the stress reaches a maximum tensile 600 to 1000 MN/sq m(90 to 150 ksi) and then decreases to compressive near the tungsten boride core. The core itself is under a compressive stress of approximately -1300 MN/sq m (-190 ksi). The effects of surface removal on core residual stress and core-initiated fracture are discussed.

  15. 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.

  16. Residual stresses and their effects on deformation

    NASA Astrophysics Data System (ADS)

    Davis, L. C.; Allison, J. E.

    1993-11-01

    Residual stresses induced by thermal expansion mismatch in metal-matrix composites are studied by three-dimensional (3-D) elastic-plastic finite element analyses. Typically, the stress-free state is 150 to 300 K above room temperature. The coefficient of thermal expansion of the matrix is 3 to 5 times larger than that of the ceramic inclusion, resulting in compressive stresses of order 200 MPa in the inclusions. Both compressive and tensile stresses can be found in the matrix. Since the stress may exceed the matrix yield strength near the particles, plastic flow occurs. The authors find a significant influence of this flow on the elastic and plastic properties of the composite. The calculated residual strains in TiC particles due to thermal expansion mismatch and external loads compare well with recent neutron diffraction experiments (Bourke et al.) The present work is the first reported three-dimensional analysis of spherical inclusions in different arrays (simple cubic (sc) and face-centered cubic (fcc)) that permit a study of particle interactions.

  17. 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.

  18. Lifetime impact on residual stress of EUV pellicle

    NASA Astrophysics Data System (ADS)

    Kim, Min-Woo; Lee, Sung-Gyu; Park, Eun-Sang; Oh, Hye-Keun

    2017-10-01

    Since EUV pellicle is very thin, It can be affected easily on its manufacturing process or the exposure process. The Pellicle has several types of stress, above all the pellicle has a residual stress from its manufacturing process. To determine the effect of residual stress on the pellicle, we calculated residual stress of several types of multi-layer pellicle by using formula. We could confirm that the residual stress has non-negligible values through the calculation results, and we obtained the thermal stress of each pellicle by using finite element method (FEM). we optimized the pellicle through comparison of total stress by plus the calculated residual stress and the thermal stress. As a result, since the p-Si core pellicle with B4C capping satisfies both high transparent and low total stress, we chose p-Si core pellicle with B4C capping as a suitable pellicle.

  19. 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

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Prime, Michael B.

    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

  1. 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.

  2. The Effect of Stochastically Varying Creep Parameters on Residual Stresses in Ceramic Matrix Composites

    NASA Technical Reports Server (NTRS)

    Pineda, Evan J.; Mital, Subodh K.; Bednarcyk, Brett A.; Arnold, Steven M.

    2015-01-01

    Constituent properties, along with volume fraction, have a first order effect on the microscale fields within a composite material and influence the macroscopic response. Therefore, there is a need to assess the significance of stochastic variation in the constituent properties of composites at the higher scales. The effect of variability in the parameters controlling the time-dependent behavior, in a unidirectional SCS-6 SiC fiber-reinforced RBSN matrix composite lamina, on the residual stresses induced during processing is investigated numerically. The generalized method of cells micromechanics theory is utilized to model the ceramic matrix composite lamina using a repeating unit cell. The primary creep phases of the constituents are approximated using a Norton-Bailey, steady state, power law creep model. The effect of residual stresses on the proportional limit stress and strain to failure of the composite is demonstrated. Monte Carlo simulations were conducted using a normal distribution for the power law parameters and the resulting residual stress distributions were predicted.

  3. 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.

  4. Residual Stress Analysis in Welded Component.

    NASA Astrophysics Data System (ADS)

    Rouhi, Shahab; Yoshida, Sanichiro; Miura, Fumiya; Sasaki, Tomohiro

    Due to local heating, thermal stresses occur during welding; and residual stress and distortion result remain welding. Welding distortion has negative effects on the accuracy of assembly, exterior appearance, and various strengths of the welded structures. Up to date, a lot of experiments and numerical analysis have been developed to assess residual stress. However, quantitative estimation of residual stress based on experiment may involve massive uncertainties and complexity of the measurement process. To comprehensively understand this phenomena, it is necessary to do further researches by means of both experiment and numerical simulation. In this research, we conduct Finite Element Analysis (FEA) for a simple butt-welded metal plate specimen. Thermal input and resultant expansion are modeled with a thermal expansion FEA module and the resultant constitutive response of the material is modeled with a continuous mechanic FEA module. The residual stress is modeled based on permanent deformation occurring during the heating phase of the material. Experiments have also been carried out to compare with the FEA results. Numerical and experimental results show qualitative agreement. The present work was supported by the Louisiana Board of Regents (LEQSF(2016-17)-RD-C-13).

  5. 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.

  6. Residual stress at fluid interfaces

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Murray, P.E.

    We extend the Navier-Stokes equations to allow for residual stress in Newtonian fluids. A fluid, which undergoes a constrained volume change, will have residual stress. Corresponding to every constrained volume change is an eigenstrain. We present a method to include in the equations of fluid motion the eigenstrain that is a result of the presence in a fluid of a soluble chemical species. This method is used to calculate the residual stress associated with a chemical transformation. 9 refs., 1 fig.

  7. Residual Stress Measurement and the Effect of Heat Treatment in Cladded Control Rod Drive Specimens

    NASA Astrophysics Data System (ADS)

    Bowman, Ashley; Kingston, Ed; Katsuyama, Jinya; Udagawa, Makoto; Onizawa, Kunio

    This paper presents results of residual stress measurements and modelling within the cladding and J-groove weld of Control Rod Drive (CRD) specimens in the as-welded and Post Weld Heat Treated (PWHT) states. Knowledge of the residual stresses present in CRD nozzles is critical when modelling the fracture mechanics of failures of nuclear power plant components to dictate inspections intervals and optimise plant downtime. The specimens comprised of ferritic steel blocks with 309L stainless steel cladding and a single J-groove weld attaching the 304 stainless steel nozzles. Multiple measurements were made through the thickness of the specimens in order to give biaxial residual stress profiles through all the different fusion boundaries. The results show the effect of PWHT in reducing residual stresses both in the weld and ferritic material. The beneficial use of measurements is highlighted to provide confidence in the modelled results and prevent over conservatism in integrity calculations, costing unnecessary time and money.

  8. A quasi-linear analysis of the impurity effect on turbulent momentum transport and residual stress

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Ko, S. H., E-mail: shko@nfri.re.kr; Jhang, Hogun; Singh, R.

    2015-08-15

    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 ismore » shown to cause a considerable reduction of the residual stress, which may lead to the reduction of turbulence driven intrinsic rotation.« less

  9. 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. Copyright © 2016. Published by Elsevier B.V.

  10. The effect of residual stresses induced by prestraining on fatigue life of notched specimens

    NASA Astrophysics Data System (ADS)

    Sadeler, R.; Ozel, A.; Kaymaz, I.; Totik, Y.

    2005-06-01

    The effect of tensile prestraining-induced residual stress on the fatigue life of notched steel parts was investigated. The study was performed on AISI 4140 steel. Rotating bending fatigue tests were carried out on semicircular notched specimens with different notch radii in the as-quenched and tempered conditions. Metallography of the specimens was performed by means of light optical microscopy. The finite-element method was used to evaluate the residual stress distribution near the notch region. Fatigue tests revealed fatigue life improvement for notched specimens, which changes depending on the notch radii and applied stress. Scanning electron microscopy was used to examine the fracture surfaces of the specimens.

  11. 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.

  12. A Simplified Model for the Effect of Weld-Induced Residual Stresses on the Axial Ultimate Strength of Stiffened Plates

    NASA Astrophysics Data System (ADS)

    Chen, Bai-Qiao; Guedes Soares, C.

    2018-03-01

    The present work investigates the compressive axial ultimate strength of fillet-welded steel-plated ship structures subjected to uniaxial compression, in which the residual stresses in the welded plates are calculated by a thermo-elasto-plastic finite element analysis that is used to fit an idealized model of residual stress distribution. The numerical results of ultimate strength based on the simplified model of residual stress show good agreement with those of various methods including the International Association of Classification Societies (IACS) Common Structural Rules (CSR), leading to the conclusion that the simplified model can be effectively used to represent the distribution of residual stresses in steel-plated structures in a wide range of engineering applications. It is concluded that the widths of the tension zones in the welded plates have a quasi-linear behavior with respect to the plate slenderness. The effect of residual stress on the axial strength of the stiffened plate is analyzed and discussed.

  13. 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.

  14. Theoretical modelling of residual and transformational stresses in SMA composites

    NASA Astrophysics Data System (ADS)

    Berman, J. B.; White, S. R.

    1996-12-01

    SMA composites are a class of smart materials in which shape memory alloy (SMA) actuators are embedded in a polymer matrix composite. The difference in thermal expansion between the SMA and the host material leads to residual stresses during processing. Similarly, the SMA transformations from martensite to austenite, or the reverse, also generate stresses. These stresses acting in combination can lead to SMA/epoxy interfacial debonding or microcracking of the composite phase. In this study the residual and transformational stresses are investigated for a nitinol wire embedded in a graphite/epoxy composite. A three-phase micromechanical model is developed. The nitinol wire is assumed to behave as a thermoelastic material. Nitinol austenitic and martensitic transformations are modelled using linear piecewise interpolation of experimental data. The interphase is modelled as a thermoelastic polymer. A transversely isotropic thermoelastic composite is used for the outer phase. Stress-free conditions are assumed immediately before cool down from the cure temperature. The effect of nitinol, coating and composite properties on residual and transformational stresses are evaluated. Fiber architectures favoring the axial direction decrease the magnitude of all residual stresses. A decrease in stresses at the composite/coating interface is also predicted through the use of thick, compliant coatings. Reducing the recovery strain and moving the transformation to higher temperatures were found to be most effective in reducing residual stresses.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. A stress-free model for residual stress assessment using thermoelastic stress analysis

    NASA Astrophysics Data System (ADS)

    Howell, Geoffrey; Dulieu-Barton, Janice M.; Achintha, Mithila; Robinson, Andrew F.

    2015-03-01

    Thermoelastic Stress Analysis (TSA) has been proposed as a method of obtaining residual stresses. The results of a preliminary study demonstrated that when Al-2024 plate containing holes that were plastically deformed by cold expansion process to 2% and 4% strain the thermoelastic response in the material around the hole was different to that obtained from a plate that had not experienced any plastic cold expansion (i.e. a reference specimen). This observation provides an opportunity for obtaining residual stresses based on TSA data. In many applications a reference specimen (i.e. residual stress free specimen) may not be available for comparison, so a synthetic, digital bitmap has been proposed as an alternative. An elastic finite element model is created using commercially available software Abaqus/Standard and the resultant stress field is extracted. The simulated stress field from the model is mapped onto a grid that matches the TSA pixel data from a physical reference specimen. This stress field is then converted to a ΔT/T field that can be compared to the full-field TSA data. When the reference experimental data is subtracted from the, bitmap dataset the resultant ΔT/T field is approximately zero. Further work proposes replacing the experimental reference data with that from specimens that have undergone cold expansion with the aim of revealing the regions affected by residual stress through a departure from zero in the resultant stress field. The paper demonstrates the first steps necessary for deriving the residual stresses from a general specimen using TSA.

  20. 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.

  1. 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

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

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

    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

  3. Residual stresses in shape memory alloy fiber reinforced aluminium matrix composite

    NASA Astrophysics Data System (ADS)

    Tsz Loong, Tang; Jamian, Saifulnizan; Ismail, Al Emran; Nur, Nik Hisyammudin Muhd; Watanabe, Yoshimi

    2017-01-01

    Process-induced residual stress in shape memory alloy (SMA) fiber reinforced aluminum (Al) matrix composite was simulated by ANSYS APDL. The manufacturing process of the composite named as NiTi/Al is start with loading and unloading process of nickel titanium (NiTi) wire as SMA to generate a residual plastic strain. Then, this plastic deformed NiTi wire would be embedded into Al to become a composite. Lastly, the composite is heated form 289 K to 363 K and then cooled back to 300 K. Residual stress is generated in composite because of shape memory effect of NiTi and mismatch of thermal coefficient between NiTi wire and Al matrix of composite. ANSYS APDL has been used to simulate the distribution of residual stress and strain in this process. A sensitivity test has been done to determine the optimum number of nodes and elements used. Hence, the number of nodes and elements used are 15680 and 13680, respectively. Furthermore, the distribution of residual stress and strain of nickel fiber reinforced aluminium matrix composite (Ni/Al) and titanium fiber reinforced aluminium matrix composite (Ti/Al) under same simulation process also has been simulated by ANSYS APDL as comparison to NiTi/Al. The simulation results show that compressive residual stress is generated on Al matrix of Ni/Al, Ti/Al and NiTi/Al during heating and cooling process. Besides that, they also have similar trend of residual stress distribution but difference in term of value. For Ni/Al and Ti/Al, they are 0.4% difference on their maximum compressive residual stress at 363K. At same circumstance, NiTi/Al has higher residual stress value which is about 425% higher than Ni/Al and Ti/Al composite. This implies that shape memory effect of NiTi fiber reinforced in composite able to generated higher compressive residual stress in Al matrix, hence able to enhance tensile property of the composite.

  4. Residual stresses of thin, short rectangular plates

    NASA Technical Reports Server (NTRS)

    Andonian, A. T.; Danyluk, S.

    1985-01-01

    The analysis of the residual stresses in thin, short rectangular plates is presented. The analysis is used in conjunction with a shadow moire interferometry technique by which residual stresses are obtained over a large spatial area from a strain measurement. The technique and analysis are applied to a residual stress measurement of polycrystalline silicon sheet grown by the edge-defined film growth technique.

  5. 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.

  6. Effects of Ultrasonic Nanocrystal Surface Modification on the Residual Stress, Microstructure, and Corrosion Resistance of 304 Stainless Steel Welds

    NASA Astrophysics Data System (ADS)

    Ye, Chang; Telang, Abhishek; Gill, Amrinder; Wen, Xingshuo; Mannava, Seetha R.; Qian, Dong; Vasudevan, Vijay K.

    2018-03-01

    In this study, ultrasonic nanocrystal surface modification (UNSM) of 304 stainless steel welds was carried out. UNSM effectively eliminates the tensile stress generated during welding and imparts beneficial compressive residual stresses. In addition, UNSM can effectively refine the grains and increase hardness in the near-surface region. Corrosion tests in boiling MgCl2 solution demonstrate that UNSM can significantly improve the corrosion resistance due to the compressive residual stresses and changes in the near-surface microstructure.

  7. Residual stress measurement in silicon sheet by shadow moire interferometry

    NASA Technical Reports Server (NTRS)

    Kwon, Y.; Danyluk, S.; Bucciarelli, L.; Kalejs, J. P.

    1987-01-01

    A shadow moire interferometry technique has been developed to measure residual strain in thin silicon sheet. The curvature of a segment of sheet undergoing four-point bending is analyzed to include the applied bending moments, the in-plane residual stresses, and the 'end effect' of the sheet since it is of finite length. The technique is applied to obtain residual stress distributions for silicon sheet grown by the edge-defined film-fed growth technique.

  8. Effect of thermal exposure on the residual stress relaxation in a hardened cylindrical sample under creep conditions

    NASA Astrophysics Data System (ADS)

    Radchenko, V. P.; Saushkin, M. N.; Tsvetkov, V. V.

    2016-05-01

    This paper describes the effect of thermal exposure (high-temperature exposure) ( T = 675°C) on the residual creep stress relaxation in a surface hardened solid cylindrical sample made of ZhS6UVI alloy. The analysis is carried out with the use of experimental data for residual stresses after micro-shot peening and exposures to temperatures equal to T = 675°C during 50, 150, and 300 h. The paper presents the technique for solving the boundary-value creep problem for the hardened cylindrical sample with the initial stress-strain state under the condition of thermal exposure. The uniaxial experimental creep curves obtained under constant stresses of 500, 530, 570, and 600 MPa are used to construct the models describing the primary and secondary stages of creep. The calculated and experimental data for the longitudinal (axial) tensor components of residual stresses are compared, and their satisfactory agreement is determined.

  9. Effects of Cutting Edge Microgeometry on Residual Stress in Orthogonal Cutting of Inconel 718 by FEM.

    PubMed

    Shen, Qi; Liu, Zhanqiang; Hua, Yang; Zhao, Jinfu; Lv, Woyun; Mohsan, Aziz Ul Hassan

    2018-06-14

    Service performance of components such as fatigue life are dramatically influenced by the machined surface and subsurface residual stresses. This paper aims at achieving a better understanding of the influence of cutting edge microgeometry on machined surface residual stresses during orthogonal dry cutting of Inconel 718. Numerical and experimental investigations have been conducted in this research. The cutting edge microgeometry factors of average cutting edge radius S¯, form-factor K , and chamfer were investigated. An increasing trend for the magnitudes of both tensile and compressive residual stresses was observed by using larger S¯ or introducing a chamfer on the cutting edges. The ploughing depth has been predicted based on the stagnation zone. The increase of ploughing depth means that more material was ironed on the workpiece subsurface, which resulted in an increase in the compressive residual stress. The thermal loads were leading factors that affected the surface tensile residual stress. For the unsymmetrical honed cutting edge with K = 2, the friction between tool and workpiece and tensile residual stress tended to be high, while for the unsymmetrical honed cutting edge with K = 0.5, the high ploughing depth led to a higher compressive residual stress. This paper provides guidance for regulating machine-induced residual stress by edge preparation.

  10. On the residual stress modeling of shot-peened AISI 4340 steel: finite element and response surface methods

    NASA Astrophysics Data System (ADS)

    Asgari, Ali; Dehestani, Pouya; Poruraminaie, Iman

    2018-02-01

    Shot peening is a well-known process in applying the residual stress on the surface of industrial parts. The induced residual stress improves fatigue life. In this study, the effects of shot peening parameters such as shot diameter, shot speed, friction coefficient, and the number of impacts on the applied residual stress will be evaluated. To assess these parameters effect, firstly the shot peening process has been simulated by finite element method. Then, effects of the process parameters on the residual stress have been evaluated by response surface method as a statistical approach. Finally, a strong model is presented to predict the maximum residual stress induced by shot peening process in AISI 4340 steel. Also, the optimum parameters for the maximum residual stress are achieved. The results indicate that effect of shot diameter on the induced residual stress is increased by increasing the shot speed. Also, enhancing the friction coefficient magnitude always cannot lead to increase in the residual stress.

  11. Finite element residual stress analysis of induction heating bended ferritic steel piping

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kima, Jong Sung; Kim, Kyoung-Soo; Oh, Young-Jin

    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 residualmore » 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.« less

  12. The relationships between residual stress relaxation and texture development in AZ31 Mg alloys via the vibratory stress relief technique

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Wang, Jia-Siang, E-mail: andy304312003@yahoo.com.tw; Hsieh, Chih-Chun, E-mail: jeromehsieh@gmail.com; Lai, Hsuan-Han, E-mail: g099066020@mail.nchu.edu.tw

    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 residualmore » 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.« less

  13. Effects of Cryogenic Treatment on the Residual Stress and Mechanical Properties of an Aerospace Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Chen, P.; Malone, T.; Bond, R.; Torres, P.

    2001-01-01

    Investigators at Marshall Space Flight Center (MSFC) are studying the potential benefits of cryogenic treatment for aerospace Aluminum (Al) alloys. This paper reports the effects of cryogenic treatment on residual stress, tensile strength, hardness, fatigue life, and stress corrosion cracking (SCC) resistance.

  14. Effects of Cryogenic Treatment on the Residual Stress and Mechanical Properties of an Aerospace Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Chen, Po; Malone, Tina; Bod, Robert; Torres, Pablo

    2000-01-01

    Investigators at Marshall Space Flight Center (MSFC) are studying the potential benefits of cryogenic treatment for aerospace Aluminum (Al) alloys. This paper reports the effects of cryogenic treatment on residual stress, tensile strength, hardness, fatigue life, and stress corrosion cracking (SCC) resistance.

  15. Effect of annealing induced residual stress on the resonance frequency of SiO2 microcantilevers

    NASA Astrophysics Data System (ADS)

    Balasubramanian, S.; Prabakar, K.; Tripura Sundari, S.

    2018-04-01

    In the present work, effect of residual stress, induced due to annealing of SiO2 microcantilevers (MCs) on their resonance frequency is studied. SiO2MCs of various dimensions were fabricated using direct laser writer & wet chemical etching method and were annealed at 800 °C in oxygen environment, post release. The residual stress was estimated from the deflection profile of the MCs measured using 3D optical microscope, before and after annealing. Resonance frequency of the MCs was measured using nano-vibration analyzer and was found to change after annealing. Further the frequency shift was found to depend on the MC dimensions. This is attributed to the large stress gradients induced by annealing and associated stiffness changes.

  16. Residual stresses in AM fabricated ball during a heating process

    NASA Astrophysics Data System (ADS)

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

    2018-05-01

    The present study is devoted to the problem of residual stresses calculation in AM fabricated ball during heating. Strains of the ball are assumed to be small, which allows to use the apparatus of the theory of thermoelastoplastic akin to Prandtl and Reuss. The problem of the evolution of the field of residual stresses in the ball at a given temperature on its external border is solved. The heat conduction equation and the equilibrium equations may be independently integrated when the hypothesis of the insignificance of the coupled effects of thermal and mechanical processes is adopted. The fields of residual stresses and displacements are computed.

  17. Measurement of edge residual stresses in glass by the phase-shifting method

    NASA Astrophysics Data System (ADS)

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

    2011-05-01

    Control and measurement of residual stress in glass is of great importance in the industrial field. Since glass is a birefringent material, the residual stress analysis is based mainly on the photoelastic method. This paper considers two methods of automated analysis of membrane residual stress in glass sheets, based on the phase-shifting concept in monochromatic light. In particular these methods are the automated versions of goniometric compensation methods of Tardy and Sénarmont. The proposed methods can effectively replace manual methods of compensation (goniometric compensation of Tardy and Sénarmont, Babinet and Babinet-Soleil compensators) provided by current standards on the analysis of residual stresses in glasses.

  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. High performance computation of residual stress and distortion in laser welded 301L stainless sheets

    DOE PAGES

    Huang, Hui; Tsutsumi, Seiichiro; Wang, Jiandong; ...

    2017-07-11

    Transient thermo-mechanical simulation of stainless plate laser welding process was performed by a highly efficient and accurate approach-hybrid iterative substructure and adaptive mesh method. Especially, residual stress prediction was enhanced by considering various heat effects in the numerical model. The influence of laser welding heat input on residual stress and welding distortion of stainless thin sheets were investigated by experiment and simulation. X-ray diffraction (XRD) and contour method were used to measure the surficial and internal residual stress respectively. Effect of strain hardening, annealing and melting on residual stress prediction was clarified through a parametric study. It was shown thatmore » these heat effects must be taken into account for accurate prediction of residual stresses in laser welded stainless sheets. Reasonable agreement among residual stresses by numerical method, XRD and contour method was obtained. Buckling type welding distortion was also well reproduced by the developed thermo-mechanical FEM.« less

  20. High performance computation of residual stress and distortion in laser welded 301L stainless sheets

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Huang, Hui; Tsutsumi, Seiichiro; Wang, Jiandong

    Transient thermo-mechanical simulation of stainless plate laser welding process was performed by a highly efficient and accurate approach-hybrid iterative substructure and adaptive mesh method. Especially, residual stress prediction was enhanced by considering various heat effects in the numerical model. The influence of laser welding heat input on residual stress and welding distortion of stainless thin sheets were investigated by experiment and simulation. X-ray diffraction (XRD) and contour method were used to measure the surficial and internal residual stress respectively. Effect of strain hardening, annealing and melting on residual stress prediction was clarified through a parametric study. It was shown thatmore » these heat effects must be taken into account for accurate prediction of residual stresses in laser welded stainless sheets. Reasonable agreement among residual stresses by numerical method, XRD and contour method was obtained. Buckling type welding distortion was also well reproduced by the developed thermo-mechanical FEM.« less

  1. 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.

  2. Residual Stress Analysis Based on Acoustic and Optical Methods.

    PubMed

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

    2016-02-16

    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.

  3. 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.

  4. 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.

  5. Nanohardness and Residual Stress in TiN Coatings.

    PubMed

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

    2011-05-17

    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.

  6. Analysis of residual stress state in sheet metal parts processed by single point incremental forming

    NASA Astrophysics Data System (ADS)

    Maaß, F.; Gies, S.; Dobecki, M.; Brömmelhoff, K.; Tekkaya, A. E.; Reimers, W.

    2018-05-01

    The mechanical properties of formed metal components are highly affected by the prevailing residual stress state. A selective induction of residual compressive stresses in the component, can improve the product properties such as the fatigue strength. By means of single point incremental forming (SPIF), the residual stress state can be influenced by adjusting the process parameters during the manufacturing process. To achieve a fundamental understanding of the residual stress formation caused by the SPIF process, a valid numerical process model is essential. Within the scope of this paper the significance of kinematic hardening effects on the determined residual stress state is presented based on numerical simulations. The effect of the unclamping step after the manufacturing process is also analyzed. An average deviation of the residual stress amplitudes in the clamped and unclamped condition of 18 % reveals, that the unclamping step needs to be considered to reach a high numerical prediction quality.

  7. 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

  8. 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.

  9. 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.

  10. 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

  11. Investigating Resulting Residual Stresses during Mechanical Forming Process

    NASA Astrophysics Data System (ADS)

    Akinlabi, Stephen A.; Fatoba, Olawale S.; Mashinini, Peter M.; Akinlabi, Esther T.

    2018-03-01

    Most manufacturing processes such as machining, welding, heat treatment, laser forming, laser cladding and, laser metal deposition, etc. are subjected to a form of heat or energy to change the geometrical shape thus changing the inherent engineering and structural properties of the material. These changes often cause the development of locked up stresses referred to as residual stresses as a result of these activities. This study reports on the residual stresses developed due to the mechanical forming process to maintain a suitable structural integrity for the formed components. The result of the analysis through the X-ray diffraction confirmed that residual stresses were induced in the manufactured parts and further revealed that residual stresses were compressive in nature as found in the parent material but with values less than the parent material.

  12. 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.

  13. Cold pulse and rotation reversals with turbulence spreading and residual stress

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Hariri, F.; Naulin, V.; Juul Rasmussen, J.

    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.more » 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.« less

  14. Residual stress evaluation of components produced via direct metal laser sintering

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kemerling, Brandon; Lippold, John C.; Fancher, Christopher M.

    Direct metal laser sintering is an additive manufacturing process which is capable of fabricating three-dimensional components using a laser energy source and metal powder particles. Despite the numerous benefits offered by this technology, the process maturity is low with respect to traditional subtractive manufacturing methods. Relationships between key processing parameters and final part properties are generally lacking and require further development. In this study, residual stresses were evaluated as a function of key process variables. The variables evaluated included laser scan strategy and build plate preheat temperature. Residual stresses were measured experimentally via neutron diffraction and computationally via finite elementmore » analysis. Good agreement was shown between the experimental and computational results. Results showed variations in the residual stress profile as a function of laser scan strategy. Compressive stresses were dominant along the build height (z) direction, and tensile stresses were dominant in the x and y directions. Build plate preheating was shown to be an effective method for alleviating residual stress due to the reduction in thermal gradient.« less

  15. Residual stress evaluation of components produced via direct metal laser sintering

    DOE PAGES

    Kemerling, Brandon; Lippold, John C.; Fancher, Christopher M.; ...

    2018-03-22

    Direct metal laser sintering is an additive manufacturing process which is capable of fabricating three-dimensional components using a laser energy source and metal powder particles. Despite the numerous benefits offered by this technology, the process maturity is low with respect to traditional subtractive manufacturing methods. Relationships between key processing parameters and final part properties are generally lacking and require further development. In this study, residual stresses were evaluated as a function of key process variables. The variables evaluated included laser scan strategy and build plate preheat temperature. Residual stresses were measured experimentally via neutron diffraction and computationally via finite elementmore » analysis. Good agreement was shown between the experimental and computational results. Results showed variations in the residual stress profile as a function of laser scan strategy. Compressive stresses were dominant along the build height (z) direction, and tensile stresses were dominant in the x and y directions. Build plate preheating was shown to be an effective method for alleviating residual stress due to the reduction in thermal gradient.« less

  16. Descriptions of crack growth behaviors in glass-ZrO2 bilayers under thermal residual stresses.

    PubMed

    Belli, Renan; Wendler, Michael; Zorzin, José I; Petschelt, Anselm; Tanaka, Carina B; Meira, Josete; Lohbauer, Ulrich

    2016-09-01

    This study was intended to separate residual stresses arising from the mismatch in coefficients of thermal expansion between glass and zirconia (ZrO2) from those stresses arising solely from the cooling process. Slow crack growth experimentes were undertaken to demonstrate how cracks grow in different residual stress fields. Aluminosilicate glass discs were sintered onto ZrO2 to form glass-ZrO2 bilayers. Glass discs were allowed to bond to the ZrO2 substrate during sintering or prevented from bonding by means of coating the ZrO2 with a thin boron nitrade coating. Residual stress gradients on "bonded" and "unbonded" bilayers were assessed using birefringence measurements. Unbonded glass discs were further tested under biaxial flexure in dynamic fatigue conditions in order to evaluate the effect of residual stress on the slow crack growth behavior. When fast-ccoling was induced, residual tensile stresses on the glass increased significantly on the side toward the ZrO2 substrate. By allowing the bond between glass and ZrO2, those tensile stresses observed in unbonded specimens are overwhelmed by the contraction mismatch stresses between the ZrO2 substrate and the glassy overlayer. Specimens containing residual tensile stresses on the bending surface showed a time-dependent strength increase in relation to stress-free annealed samples in the dynamic biaxial bending test, with this effect being dependent on the magnitude of the residual tensile stress. The phenomenon observed is explained here on the basis of the water toughening effect, in which water diffuses into the glass promoting local swelling. An additional residual tensile stress at the crack tip adds an applied-stress-independent (Kres) term to the total tip stress intensity factor (Ktip), increasing the stress-enhanced diffusion and the shielding of the crack tip through swelling of the crack faces. Residual stresses in the glass influence the crack growth behavior of veneered-ZrO2 bilayered dental prostheses

  17. Residual stress control and design of next-generation ultra-hard gear steels

    NASA Astrophysics Data System (ADS)

    Qian, Yana

    In high power density transmission systems, Ni-Co secondary hardening steels have shown great potential for next-generation gear applications due to their excellent strength, toughness and superior fatigue performance. Study of residual stress generation and evolution in Ferrium C61 and C67 gear steels revealed that shot peening and laser peening processes effectively produce desired beneficial residual stress in the steels for enhanced fatigue performance. Surface residual stress levels of -1.4GPa and -1.5GPa were achieved in shot peened C61 and laser peened C67, respectively, without introducing large surface roughness or defects. Higher compressive residual stress is expected in C67 according to a demonstrated correlation between attainable residual stress and material hardness. Due to the lack of appropriate shot media, dual laser peening is proposed for future peening optimization in C67. A novel non-destructive synchrotron radiation technique was implemented and applied for the first time for residual stress distribution analysis in gear steels with large composition and property gradients. Observed substantial residual stress redistribution and material microstructure change during the rolling contact fatigue screening test with extremely high 5.4GPa load indicates the unsuitability of the test as a fatigue life predictor. To exploit benefits of higher case hardness and associated residual stress, a new material and process (CryoForm70) aiming at 70Rc surface hardness was designed utilizing the systems approach based on thermodynamics and secondary hardening mechanisms. The composition design was first validated by the excellent agreement between experimental and theoretical core martensite start temperature in the prototype. A novel cryogenic deformation process was concurrently designed to increase the case martensite volume fraction from 76% to 92% for enhanced strengthening efficiency and surface hardness. High temperature vacuum carburizing was

  18. Size Dependence of Residual Thermal Stresses in Micro Multilayer Ceramic Capacitors by Using Finite Element Unit Cell Model Including Strain Gradient Effect

    NASA Astrophysics Data System (ADS)

    Jiang, W. G.; Xiong, C. A.; Wu, X. G.

    2013-11-01

    The residual thermal stresses induced by the high-temperature sintering process in multilayer ceramic capacitors (MLCCs) are investigated by using a finite-element unit cell model, in which the strain gradient effect is considered. The numerical results show that the residual thermal stresses depend on the lateral margin length, the thickness ratio of the dielectrics layer to the electrode layer, and the MLCC size. At a given thickness ratio, as the MLCC size is scaled down, the peak shear stress reduces significantly and the normal stresses along the length and thickness directions change slightly with the decrease in the ceramic layer thickness t d as t d > 1 μm, but as t d < 1 μm, the normal stress components increase sharply with the increase in t d. Thus, the residual thermal stresses induced by the sintering process exhibit strong size effects and, therefore, the strain gradient effect should be taken into account in the design and evaluation of MLCC devices

  19. Effects of interface morphology and TGO thickness on residual stress of EB-PVD thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Chen, Jianwei; Zhao, Yang; Ma, Jian

    2015-04-01

    The residual stress of electron beam-physical vapor deposition (EB-PVD) thermal barrier coatings (TBC) is complex and difficult to be obtained. In this paper, the interface morphology of TBCs subjected to cyclic heating and cooling was observed by SEM. Based on the thermal elastic-plastic finite method, corresponding interface model of TBCs was established. The residual stress of EB-PVD TBCs with different interface morphologies and TGO thicknesses was calculated using the FE method without regard to the presence of cracks and defects. The result shows that the distribution of residual stress is significantly affected by the interface morphology, and the growth of TGO also has influence on the residual stress of TC and TGO.

  20. Effects of shot-peening residual stresses on the fracture and crack-growth properties of D6AC steel

    NASA Technical Reports Server (NTRS)

    Elber, W.

    1974-01-01

    The fracture strength and cyclic crack-growth properties of surface-flawed, shot-peened D6AC steel plate were investigated. For short crack lengths (up to 1.5 mm) simple linear elastic fracture mechanics - based only on applied loading - did not predict the fracture strengths. Also, Paris' Law for cyclic crack growth did not correlate the crack-growth behavior. To investigate the effect of shot-peening, additional fracture and crack-growth tests were performed on material which was precompressed to remove the residual stresses left by the shot-peening. Both tests and analysis show that shot-peening residual stresses influence the fracture and crack-growth properties of the material. This report presents the analytical method of compensating for residual stresses and the fracture and cyclic crack-growth test results and predictions.

  1. 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.

  2. A method to separate and quantify the effects of indentation size, residual stress and plastic damage when mapping properties using instrumented indentation

    NASA Astrophysics Data System (ADS)

    Hou, X. D.; Jennett, N. M.

    2017-11-01

    Instrumented indentation is a convenient and increasingly rapid method of high resolution mapping of surface properties. There is, however, significant untapped potential for the quantification of these properties, which is only possible by solving a number of serious issues that affect the absolute values for mechanical properties obtained from small indentations. The three most pressing currently are the quantification of: the indentation size effect (ISE), residual stress, and pile-up and sink-in—which is itself affected by residual stress and ISE. Hardness based indentation mapping is unable to distinguish these effects. We describe a procedure that uses an elastic modulus as an internal reference and combines the information available from an indentation modulus map, a hardness map, and a determination of the ISE coefficient (using self-similar geometry indentation) to correct for the effects of stress, pile up and the indentation size effect, to leave a quantified map of plastic damage and grain refinement hardening in a surface. This procedure is used to map the residual stress in a cross-section of the machined surface of a previously stress free metal. The effect of surface grinding is compared to milling and is shown to cause different amounts of work hardening, increase in residual stress, and surface grain size reduction. The potential use of this procedure for mapping coatings in cross-section is discussed.

  3. An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel

    NASA Astrophysics Data System (ADS)

    Wu, Amanda S.; Brown, Donald W.; Kumar, Mukul; Gallegos, Gilbert F.; King, Wayne E.

    2014-12-01

    Additive manufacturing (AM) technology provides unique opportunities for producing net-shape geometries at the macroscale through microscale processing. This level of control presents inherent trade-offs necessitating the establishment of quality controls aimed at minimizing undesirable properties, such as porosity and residual stresses. Here, we perform a parametric study into the effects of laser scanning pattern, power, speed, and build direction in powder bed fusion AM on residual stress. In an effort to better understand the factors influencing macroscale residual stresses, a destructive surface residual stress measurement technique (digital image correlation in conjunction with build plate removal and sectioning) has been coupled with a nondestructive volumetric evaluation method ( i.e., neutron diffraction). Good agreement between the two measurement techniques is observed. Furthermore, a reduction in residual stress is obtained by decreasing scan island size, increasing island to wall rotation to 45 deg, and increasing applied energy per unit length (laser power/speed). Neutron diffraction measurements reveal that, while in-plane residual stresses are affected by scan island rotation, axial residual stresses are unchanged. We attribute this in-plane behavior to misalignment between the greatest thermal stresses (scan direction) and largest part dimension.

  4. Effects of Cooling Rate on Precipitate Evolution and Residual Stresses in Al-Si-Mn-Mg Casting Alloy

    NASA Astrophysics Data System (ADS)

    Lee, Eunkyung; Walde, Caitlin; Mishra, Brajendra

    2018-07-01

    The residual stresses with different heat treatment conditions have been measured and correlated with the microstructural behavior of AA365. 30 and 100 K/min cooling of AA365 inhibited the transformation of precipitates under 773 K, respectively. The alloy cooled at 30 and 100 K/min exhibited tensile residual stresses of 6.2 and 5.4 MPa, respectively, while the alloy cooled at 1 and 10 K/min showed compressive stresses of - 12.8 and - 10.3 MPa, respectively. The formation β', β″, and other intermetallic compounds affected the compressive residual stresses, and that the fracture of the brittle intermetallic phases could reduce the extent of residual stresses in the lattice through plastic deformation.

  5. Effects of Cooling Rate on Precipitate Evolution and Residual Stresses in Al-Si-Mn-Mg Casting Alloy

    NASA Astrophysics Data System (ADS)

    Lee, Eunkyung; Walde, Caitlin; Mishra, Brajendra

    2018-03-01

    The residual stresses with different heat treatment conditions have been measured and correlated with the microstructural behavior of AA365. 30 and 100 K/min cooling of AA365 inhibited the transformation of precipitates under 773 K, respectively. The alloy cooled at 30 and 100 K/min exhibited tensile residual stresses of 6.2 and 5.4 MPa, respectively, while the alloy cooled at 1 and 10 K/min showed compressive stresses of - 12.8 and - 10.3 MPa, respectively. The formation β', β″, and other intermetallic compounds affected the compressive residual stresses, and that the fracture of the brittle intermetallic phases could reduce the extent of residual stresses in the lattice through plastic deformation.

  6. Weld residual stresses and plastic deformation

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Rybicki, E.; Shiratori, M.

    1989-01-01

    Residual stresses due to welding can play a primary role in the performance of piping systems and pressure vessels. The stresses are high, in the range of the yield stress of the material, and can influence the fatigue and fracture behavior as well as component service life. Thus, it is important to have an understanding of weld residual stresses. The papers in this section address the important topic of residual stresses and failure analysis. The paper by Boyles reviews computer simulation in the prediction and analysis of fatigue, fracture, and creep of welded structures. The growing use of expert systemsmore » for these purposes is also covered. Karisson, et al, determine the deformations and stresses during the butt-welding of a pipe. The determination of residual deformations and stresses is also presented. Oddy, Goldak, and McDill propose a method to incorporate transformation plasticity in a finite element program. A three-dimensional analysis of a short longitudinal pipe weld in a typical pressure vessel steel is presented. Chaaban, Morin, Ma, and Bazergui study the influence of ligament thickness, strain hardening, expansion sequence, and level of applied expansion pressure on the interference fit in a model of a tube-to-tubesheet joint in a heat exchanger. This section contains papers dealing with models for plastic deformation. Imatani, Teraura, and Inoue formulate a viscoplastic constitutive model based on an anisotropic yield criterion. Comparisons with experimental results obtained using thin walled tubular specimens made from SUS 304 stainless steel show that the present yield criterion adequately accounts for prior deformation history. Niitsu, Horiguchi, and Ikegami investigate the plastic behavior of S25C mild steel tubular specimens subjected to combined axial and torsional loading at both constant and variable temperatures.« less

  7. 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.

  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. 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

  10. 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.

  11. Measurement of residual stresses by the moire method

    NASA Astrophysics Data System (ADS)

    Sciammarella, C. A.; Albertazzi, A., Jr.

    Three different applications of the moire method to the determination of residual stresses and strains are presented. The three applications take advantage of the property of ratings to record the changes of the surface they are printed on. One of the applications deals with thermal residual stresses, another with contact residual stress and the third one is a generalization of the blind hole technique. This last application is based on a computer assisted moire technique and on the generalization of the quasi-heterodyne techniques of fringe pattern analysis.

  12. 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.

  13. Measuring depth profiles of residual stress with Raman spectroscopy

    DOE Office of Scientific and Technical Information (OSTI.GOV)

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

    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 residualmore » 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.« less

  14. 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

  15. Study on the residual stress relaxation in girth-welded steel pipes under bending load using diffraction methods

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Hempel, Nico; Bunn, Jeffrey R.; Nitschke-Pagel, Thomas

    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

  16. 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.

  17. 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.

  18. The effects of shot-peening residual stresses on the fracture and crack growth properties of D6AC steel

    NASA Technical Reports Server (NTRS)

    Elber, W.

    1973-01-01

    The fracture strength and cyclic crack-growth properties of surface-flawed, shot-peened D6AC steel plate were investigated. For short crack lengths (up to 1.5mm) simple linear elastic fracture mechanics - based only on applied loading - did not predict the fracture strengths. Also, Paris' Law for cyclic crack growth did not correlate the crack-growth behavior. To investigate the effect of shot-peening, additional fracture and crack-growth tests were performed on material which was precompressed to remove the residual stresses left by the shot-peening. Both tests and analysis show that the shot-peening residual stresses influence the fracture and crack-growth properties of the material. The analytical method of compensating for residual stresses and the fracture and cyclic crack-growth test results and predictions are presented.

  19. Evolution of residual stresses in micro-arc oxidation ceramic coatings on 6061 Al alloy

    NASA Astrophysics Data System (ADS)

    Shen, Dejiu; Cai, Jingrui; Guo, Changhong; Liu, Peiyu

    2013-11-01

    Most researches on micro-arc oxidation mainly focus on the application rather than discovering the evolution of residual stresses. However, residual stresses in the surface coatings of structural components have adverse effects on their properties, such as fatigue life, dimensional stability and corrosion resistance, etc. The micro-arc oxidation ceramic coatings are produced on the surfaces of 6061 aluminum alloy by a homemade asymmetric AC type of micro-arc oxidation equipment of 20 kW. A constant current density of 4.4±0.1 A/dm2 and a self-regulated composite electrolyte are used. The micro-arc oxidation treatment period ranges from 10 min to 40 min, and the thickness of the ceramic coatings is more than 20 μm. Residual stresses attributed to γ-Al2O3 constituent in the coatings at different micro-arc oxidation periods are analyzed by an X-ray diffractometer using the sin2 ψ method. The analysis results show that the residual stress in the ceramic coatings is compressive in nature, and it increases first and then decreases with micro-arc oxidation time increase. The maximum stress value is 1 667±20 MPa for period of 20 min. Through analyzing the coating thickness, surface morphology and phase composition, it is found that the residual stress in the ceramic coatings is linked closely with the coating growth, the phase composition and the micro cracks formed. It is also found that both the heat treatment and the ultrasonic action release remarkably the residual compressive stress. The heat treatment makes the residual compressive stress value decrease 1 378 MPa. The ultrasonic action even alters the nature of the residual stress, making the residual compressive stress change into a residual tensile stress.

  20. Effect of tempering treatment upon the residual stress of bimetallic roll

    NASA Astrophysics Data System (ADS)

    Sano, Y.; Noda, N.-A.; Takase, Y.; Torigoe, R.; Tsuboi, K.; Aridi, M. R.; Sanada, Y.; Lan, L. Y.

    2018-06-01

    Bimetallic rolls are widely used in steel rolling industries because of the excellent hardness, wear resistance, and high temperature properties. However, thermal stress is produced by heating-cooling thermal cycles, which is a great challenge for their practical application. Indeed, if severe thermal tensile stress is introduced into these rolls, it can assist the thermal cracks to propagate, even lead to the overall failure of rolls. In this paper, we investigated the effect of tempering treatment on the residual stress after the bimetallic rolls were subjected to quenching. Compared with the non-uniform heating-quenching process, the tempering process makes the maximum stress at the core decreased by 15% (from 275 MPa to 234 MPa) with considering martensite transformation but decreased by 26% (from 275 MPa to 201 MPa) without considering martensite transformation. For tempering process after uniform heating quenching, the maximum stress at the core decreases by 24% from 357 MPa to 273 MPa with considering martensite transformation but decreases by 30% from 357 MPa to 246 MPa without considering martensite transformation. And compared with the non-uniform heating-quenching process, the double tempering process makes the maximum stress at the core decreased by 8% (from 275 MPa to 253 MPa) with considering martensite transformation but decreased by 27% (from 275 MPa to 200 MPa) without considering martensite transformation.

  1. Investigation on the Effect of Mold Constraints and Cooling Rate on Residual Stress During the Sand-Casting Process of 1086 Steel by Employing a Thermomechanical Model

    NASA Astrophysics Data System (ADS)

    Baghani, Amir; Davami, Parviz; Varahram, Naser; Shabani, Mohsen Ostad

    2014-06-01

    In this study, the effects of mold constraints and cooling rate on residual stress were analyzed during the shaped casting process. For this purpose, an H-shaped sample was designed in which the contraction of its middle portion is highly restricted by the mold during the cooling process. The effects of an increasing cooling rate combined with mold constraints were analyzed by reducing the thickness of the middle portion in the second sample. A three-dimensional coupled temperature-displacement analysis was performed in finite-element code ABAQUS to simulate residual stress distribution, and then numerical results were verified by the hole-drilling strain-gauge method. It was concluded that the mold constraints have a greater effect on the values of residual stress than the cooling rate (thin section) in steel sand casting. Increasing the cooling rate would increase the amount of residual stress, only in the presence of mold constraints. It is also suggested that employing the elastic-plastic stress model for the sand mold will satisfy the experimental results and avoid exaggerated values of residual stress in simulation.

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Everhart, Wesley A.; Lee, Jordan D.; Broecker, Daniel J.

    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.

  3. Neutron diffraction studies of laser welding residual stresses

    NASA Astrophysics Data System (ADS)

    Petrov, Peter I.; Bokuchava, Gizo D.; Papushkin, Igor V.; Genchev, Gancho; Doynov, Nikolay; Michailov, Vesselin G.; Ormanova, Maria A.

    2016-01-01

    The residual stress and microstrain distribution induced by laser beam welding of the low-alloyed C45 steel plate was investigated using high-resolution time-of-flight (TOF) neutron diffraction. The neutron diffraction experiments were performed on FSD diffractometer at the IBR-2 pulsed reactor in FLNP JINR (Dubna, Russia). The experiments have shown that the residual stress distribution across weld seam exhibit typical alternating sign character as it was observed in our previous studies. The residual stress level is varying in the range from -60 MPa to 450 MPa. At the same time, the microstrain level exhibits sharp maxima at weld seam position with maximal level of 4.8·10-3. The obtained experimental results are in good agreement with FEM calculations according to the STAAZ model. The provided numerical model validated with measured data enables to study the influence of different conditions and process parameters on the development of residual welding stresses.

  4. Investigation of residual stresses in shape memory alloy (SMA) composites

    NASA Astrophysics Data System (ADS)

    Berman, Justin Bradley

    Shape memory alloy (SMA) composites are a class of smart materials in which SMA actuators are embedded in a host matrix. The shape memory effect allows for stress induced phase transformations and large recoverable strains that make SMA composites promising candidates for structural shape/vibration control, impact absorption, aircraft deicing or in-flight airfoil shape control systems. However, the difference in thermal expansion between the SMA and the host material leads to residual stresses during processing. In addition, the SMA transformation from martensite to austenite, or the reverse, also generate stresses. These stresses acting in combination can lead to SMA/polymer interfacial debonding or microcracking of the host matrix. The present work was undertaken to study the behavior of nitinol shape memory alloys embedded in epoxy and glass/epoxy matrices and to investigate the development of residual stresses during their manufacture and actuation. A three-phase concentric cylinder micromechanics model and an SMA composite thermoelastic beam theory were developed to analyze the micromechanical and structural-level thermal and transformational stresses for nitinol composites induced by nitinol wires embedded in a host matrix. A series of warpage experiments were conducted on nitinol composite beams during heating cycles to provide experimental validation of model predictions and to assess their thermoelastic structural behavior under non-mechanical loading. Micromechanical model results indicate that excessive residual hoop stresses in nitino/graphite/epoxy composites leads to radial cracking around the embedded nitinol wires. Based on modeling results, the most important factor in reducing residual stresses (and thereby preventing radial cracking) is increasing the level of recovery strain for the nitinol wire. The SMA composite beam model agrees well with experimental data captured for the nitinol/epoxy beam series. Warpage experiments on nitinol

  5. 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

  6. Effect of Thermal cycles and Dimensions of the Geometry on Residual stress of the Alumina-Kovar Joint

    NASA Astrophysics Data System (ADS)

    Mishra, Srishti; Pal, Snehanshu; Karak, Swapan Kumar; Shah, Sejal; Venakata Nagaraju, M.; Chakraborty, Arun Kumar

    2018-03-01

    Finite element method is employed to determine the effect of variation of residual stress with dimension and the stress generated under its working condition along the Kovar. 3 different dimensions of Alumina-Kovar joint with height to diameter ratio of 3/10, using TiCuSil as a filler material. Transient Structural Analysis is carried out for three different dimensions (diameter × height) (i) 60mm × 20mm (Geometry 1) (ii) 90mm × 20mm (Geometry 2) (iii) 120mm × 20mm (Geometry 3). A comparative study has been carried out between the residual stresses developed in the brazed joint that have undergone 5 thermal cycles subsequent to brazing and that between the brazed joint. The heating and cooling rates from the brazed temperature is 10°C/up to room temperature. The brazing temperature and holding time considered for the analysis are 900°C and 10 minutes. Representative Volume Element (RVE) model is used for simulation. Sparse Matrix Direct Solver method is used to evaluate the results, using Augmented Lagrange method formulation in the contact region. All the simulations are performed in ANSYS Workbench 15.0, using solver target Mechanical APDL. From, the above simulations it is observed high concentration of residual stress is observed along the filler region i.e. in between Alumina and Kovar, as a result of difference in coefficient of thermal expansion between Alumina and Kovar. The residual stress decreases with increasing dimensions of the geometry and upon application of thermal cycles, subsequent to brazing.

  7. Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

    NASA Technical Reports Server (NTRS)

    Gabb, Timothy P.; Rogers, Richard B.; Nesbitt, James A.; Puleo, Bernadette J.; Miller, Robert A.; Telesman, Ignacy; Draper, Susan L.; Locci, Ivan E.

    2017-01-01

    Protective ductile coatings will be necessary to mitigate oxidation and corrosion attack on superalloy disks exposed to increasing operating temperatures in some turbine engine environments. However, such coatings must be resistant to harmful surface cracking during service. The objective of this study was to investigate how residual stresses evolve in such coatings. Cylindrical gage fatigue specimens of powder metallurgy-processed disk superalloy LSHR were coated with a NiCrY coating, shot peened, and then subjected to fatigue in air at room and high temperatures. The effects of shot peening and fatigue cycling on average residual stresses and other aspects of the coating were assessed. Shot peening did induce beneficial compressive residual stresses in the coating and substrate. However, these stresses became more tensile in the coating with subsequent heating and contributed to cracking of the coating in long intervals of cycling at 760 C. Substantial compressive residual stresses remained in the substrate adjacent to the coating, sufficient to suppress fatigue cracking. The coating continued to protect the substrate from hot corrosion pitting, even after fatigue cracks initiated in the coating.

  8. Modeling of Residual Stress and Machining Distortion in Aerospace Components (PREPRINT)

    DTIC Science & Technology

    2010-03-01

    John Gayda, “The Effect of Heat Treatment on Residual Stress and Machining Distortions in Advanced Nickel Base Disk Alloys,” NASA/TM-2001-210717. 2...Wei-Tsu Wu, Guoji Li, Juipeng Tang, Shesh Srivatsa, Ravi Shankar, Ron Wallis, Padu Ramasundaram and John Gayda, “A process modeling system for heat...Materials Processing Technology 98 (2000) 189-195. 6. M.A. Rist, S. Tin, B.A. Roder, J.A. James, and M.R. Daymond , “Residual Stresses in a

  9. Residual Stress Assessment in Thin Angle Ply Tubes

    NASA Astrophysics Data System (ADS)

    Kaddour, A. S.; Al-Hassani, S. T. S.; Hinton, M. J.

    2003-05-01

    This preliminary study aims to investigate the residual stresses developed in hot cured thin-walled angle-ply filament wound tubes made of E-glass/epoxy, Kevlar/epoxy and carbon/epoxy materials. The residual stresses were estimated from change in geometry of these tubes when axially slitted at ambient temperature. Three basic deformation modes; namely opening up, closing-in and twisting, were observed and these depended on the winding angle, material and wall thickness. The residual stresses were also determined from hoop and axial strain gauges mounted on both the inner and outer surfaces at various locations around the tube. The stresses were compared with theoretical prediction based upon a linear thermo-elastic analysis. Both the predicted and measured values were found to increase with increasing hoop stiffness but there was a large discrepancy between the predicted and measured data, reaching a factor of 5 for the thinnest case. When compared with predicted failure stresses, the experimentally determined stresses were some 15% of the computed compressive strength.

  10. Residual Stresses Modeled in Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Freborg, A. M.; Ferguson, B. L.; Petrus, G. J.; Brindley, W. J.

    1998-01-01

    Thermal barrier coating (TBC) applications continue to increase as the need for greater engine efficiency in aircraft and land-based gas turbines increases. However, durability and reliability issues limit the benefits that can be derived from TBC's. A thorough understanding of the mechanisms that cause TBC failure is a key to increasing, as well as predicting, TBC durability. Oxidation of the bond coat has been repeatedly identified as one of the major factors affecting the durability of the ceramic top coat during service. However, the mechanisms by which oxidation facilitates TBC failure are poorly understood and require further characterization. In addition, researchers have suspected that other bond coat and top coat factors might influence TBC thermal fatigue life, both separately and through interactions with the mechanism of oxidation. These other factors include the bond coat coefficient of thermal expansion, the bond coat roughness, and the creep behavior of both the ceramic and bond coat layers. Although it is difficult to design an experiment to examine these factors unambiguously, it is possible to design a computer modeling "experiment" to examine the action and interaction of these factors, as well as to determine failure drivers for TBC's. Previous computer models have examined some of these factors separately to determine their effect on coating residual stresses, but none have examined all the factors concurrently. The purpose of this research, which was performed at DCT, Inc., in contract with the NASA Lewis Research Center, was to develop an inclusive finite element model to characterize the effects of oxidation on the residual stresses within the TBC system during thermal cycling as well as to examine the interaction of oxidation with the other factors affecting TBC life. The plasma sprayed, two-layer thermal barrier coating that was modeled incorporated a superalloy substrate, a NiCrAlY bond coat, and a ZrO2-8 wt % Y2O3 ceramic top coat. We

  11. A coupled creep plasticity model for residual stress relaxation of a shot-peened nickel-based superalloy

    NASA Astrophysics Data System (ADS)

    Buchanan, Dennis J.; John, Reji; Brockman, Robert A.; Rosenberger, Andrew H.

    2010-01-01

    Shot peening is a commonly used surface treatment process that imparts compressive residual stresses into the surface of metal components. Compressive residual stresses retard initiation and growth of fatigue cracks. During component loading history, shot-peened residual stresses may change due to thermal exposure, creep, and cyclic loading. In these instances, taking full credit for compressive residual stresses would result in a nonconservative life prediction. This article describes a methodical approach for characterizing and modeling residual stress relaxation under elevated temperature loading, near and above the monotonic yield strength of INI 00. The model incorporates the dominant creep deformation mechanism, coupling between the creep and plasticity models, and effects of prior plastic strain to simulate surface treatment deformation.

  12. Effect of dissolution/precipitation on the residual stress redistribution of plasma-sprayed hydroxyapatite coating on titanium substrate in simulated body fluid (SBF).

    PubMed

    Rakngarm Nimkerdphol, Achariya; Otsuka, Yuichi; Mutoh, Yoshiharu

    2014-08-01

    The residual stress distributions in hydroxyapatite (HAp) coating with and without mixed hydroxyapatite/titanium (HAp/Ti) bond coating on commercially pure Titanium substrate (cp-Ti) were evaluated by Raman piezo-spectroscopy analysis. The Raman shifted position 962cm(-1), which is the symmetrical stretching of surrounded oxygen atoms with phosphorous atom ( [Formula: see text] ), was referred to analyses of stress dependency. The piezo-spectroscopic coefficient, which is a Raman shift value per stress (cm(-1)/GPa), was fitted from the result of four-points bending test of rectangular HAp bar and as-sprayed HAp on Zn plate. The calculated values were 3.89cm(-1)/GPa for the former and 7.11cm(-1)/GPa for the latter. By using these calibrations, the compressive residual stress in HAp coating with HAp/Ti bond coating (HA-B) has been found to be distributed in the range of -137MPa to -75MPa. For the heat-treated HAp coating (HA-B-HT) specimen, the compressive residual stresses placed in the range of -40--22MPa. The changes in the values of residual stress of the HAp coating after immersion in SBF were also evaluated. The residual stress in HA-WB specimens tend to change from compressive to tensile after 30 days immersion. The HA-B-HT specimens exhibited similar behavior and reached to zero stress after the immersion. The mechanism of the changes in residual stress would be the effect of stress redistribution around melted calcium phosphate particles to remained HAp splats. Copyright © 2014 Elsevier Ltd. All rights reserved.

  13. Determination of Residual Stress Distributions in Polycrystalline Alumina using Fluorescence Microscopy

    PubMed Central

    Michaels, Chris A.; Cook, Robert F.

    2016-01-01

    Maps of residual stress distributions arising from anisotropic thermal expansion effects in a polycrystalline alumina are generated using fluorescence microscopy. The shifts of both the R1 and R2 ruby fluorescence lines of Cr in alumina are used to create maps with sub-µm resolution of either the local mean and shear stresses or local crystallographic a- and c-stresses in the material, with approximately ± 1 MPa stress resolution. The use of single crystal control materials and explicit correction for temperature and composition effects on line shifts enabled determination of the absolute values and distributions of values of stresses. Temperature correction is shown to be critical in absolute stress determination. Experimental determinations of average stress parameters in the mapped structure are consistent with assumed equilibrium conditions and with integrated large-area measurements. Average crystallographic stresses of order hundreds of MPa are determined with characteristic distribution widths of tens of MPa. The stress distributions reflect contributions from individual clusters of stress in the structure; the cluster size is somewhat larger than the grain size. An example application of the use of stress maps is shown in the calculation of stress-intensity factors for fracture in the residual stress field. PMID:27563163

  14. Thermal residual stress evaluation based on phase-shift lateral shearing interferometry

    NASA Astrophysics Data System (ADS)

    Dai, Xiangjun; Yun, Hai; Shao, Xinxing; Wang, Yanxia; Zhang, Donghuan; Yang, Fujun; He, Xiaoyuan

    2018-06-01

    An interesting phase-shift lateral shearing interferometry system was proposed to evaluate the thermal residual stress distribution in transparent specimen. The phase-shift interferograms was generated by moving a parallel plane plate. Based on analyzing the fringes deflected by deformation and refractive index change, the stress distribution can be obtained. To verify the validity of the proposed method, a typical experiment was elaborately designed to determine thermal residual stresses of a transparent PMMA plate subjected to the flame of a lighter. The sum of in-plane stress distribution was demonstrated. The experimental data were compared with values measured by digital gradient sensing method. Comparison of the results reveals the effectiveness and feasibility of the proposed method.

  15. Features of residual stresses in duplex stainless steel butt welds

    NASA Astrophysics Data System (ADS)

    Um, Tae-Hwan; Lee, Chin-Hyung; Chang, Kyong-Ho; Nguyen Van Do, Vuong

    2018-04-01

    Duplex stainless steel finds increasing use as an alternative to austenitic stainless steel, particularly where chloride or sulphide stress corrosion cracking is of primary concern, due to the excellent combination of strength and corrosion resistance. During welding, duplex stainless steel does not create the same magnitude or distribution of weld-induced residual stresses as those in welded austenitic stainless steel due to the different physical and mechanical properties between them. In this work, an experimental study on the residual stresses in butt-welded duplex stainless steel is performed utilizing the layering technique to investigate the characteristics of residual stresses in the weldment. Three-dimensional thermos-mechanical-metallurgical finite element analysis is also performed to confirm the residual stress measurements.

  16. Dependence of magnetic permeability on residual stresses in alloyed steels

    NASA Astrophysics Data System (ADS)

    Hristoforou, E.; Ktena, A.; Vourna, P.; Argiris, K.

    2018-04-01

    A method for the monitoring of residual stress distribution in steels has been developed based on non-destructive surface magnetic permeability measurements. In order to investigate the potential utilization of the magnetic method in evaluating residual stresses, the magnetic calibration curves of various ferromagnetic alloyed steels' grade (AISI 4140, TRIP and Duplex) were examined. X-Ray diffraction technique was used for determining surface residual stress values. The overall measurement results have shown that the residual stress determined by the magnetic method was in good agreement with the diffraction results. Further experimental investigations are required to validate the preliminary results and to verify the presence of a unique normalized magnetic stress calibration curve.

  17. The Effect of Laser Scan Strategy on Distortion and Residual Stresses of Arches Made With Selective Laser Melting

    NASA Technical Reports Server (NTRS)

    Bagg, Stacey D.; Sochalski-Kolbus, Lindsay M.; Bunn, Jeffrey R.

    2016-01-01

    The NASA Marshall Space Flight Center (MSFC) is developing Additive Manufacturing (AM) - both in-space AM for on-demand parts, tools, or structures, and on-earth AM for rapid, reduced-cost, small volume production of complex space-flight hardware. Selective Laser Melting (SLM) is an on-earth AM technology that MSFC is using to build Alloy 718 rocket engine components. An understanding of the SLM-718 material properties is required to design, build, and qualify these components for space flight. Residual stresses and are of particular interest for this AM process, since SLM is a series of approximately 100 micron-wide welds, where highly non-linear heating and cooling, severe thermal gradients and repeated thermal cycling can result in high residual stresses within the component. These stresses may cause degraded material properties, and warp or distort the geometry of the SLM component. The distortions can render the component out-of-tolerance when inspected, and even interrupt or halt the build process if the warped material prevents the SLM machine from operating properly. The component must be scrapped and re-designed, which is time consuming and costly. If residual stresses are better understood, and can be predicted, these effects can be mitigated early in the component's design. the compressive residual stresses in the z-direction were highest in the chess sample, followed by island then continuous. This may be due to the binding nature of the segments

  18. 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.

  19. Residual Stresses and Other Properties of Teardrops

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Stroud, Mary Ann; Veirs, Douglas Kirk; Berg, John M.

    The Department of Energy’s 3013 Standard for packaging plutonium-bearing materials for storage up to fifty years specifies a minimum of two individually welded, nested containers herein referred to as the 3013 outer and the 3013 inner.1 Stress corrosion cracking (SCC) is a potential failure mechanism for 3013 inner containers.2,3 The bagless transfer container (BTC), a 3013 inner container used by Hanford and Savanna River Site (SRS) made from 304L stainless steel (SS), poses the greatest concern for SCC.4,5 The Surveillance and Monitoring Program (SMP) use stressed metal samples known as teardrops as screening tools in SCC studies to evaluate factorsmore » that could result in cracks in the 3013 containers.6,7 This report provides background information on the teardrops used in the Los Alamos National Laboratory (LANL) SMP studies including method of construction, composition and variability. In addition, the report discusses measurements of residual stresses in teardrops and compares the results with residual stresses in BTCs reported previously.4 Factors affecting residual stresses, including teardrop dimensions and surface finish, are also discussed.« less

  20. Verification and Validation of Residual Stresses in Bi-Material Composite Rings

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Nelson, Stacy Michelle; Hanson, Alexander Anthony; Briggs, Timothy

    Process-induced residual stresses commonly occur in composite structures composed of dissimilar materials. These residual stresses form due to differences in the composite materials’ coefficients of thermal expansion and the shrinkage upon cure exhibited by polymer matrix materials. Depending upon the specific geometric details of the composite structure and the materials’ curing parameters, it is possible that these residual stresses could result in interlaminar delamination or fracture within the composite. Therefore, the consideration of potential residual stresses is important when designing composite parts and their manufacturing processes. However, the experimental determination of residual stresses in prototype parts can be time andmore » cost prohibitive. As an alternative to physical measurement, it is possible for computational tools to be used to quantify potential residual stresses in composite prototype parts. Therefore, the objectives of the presented work are to demonstrate a simplistic method for simulating residual stresses in composite parts, as well as the potential value of sensitivity and uncertainty quantification techniques during analyses for which material property parameters are unknown. Specifically, a simplified residual stress modeling approach, which accounts for coefficient of thermal expansion mismatch and polymer shrinkage, is implemented within the Sandia National Laboratories’ developed SIERRA/SolidMechanics code. Concurrent with the model development, two simple, bi-material structures composed of a carbon fiber/epoxy composite and aluminum, a flat plate and a cylinder, are fabricated and the residual stresses are quantified through the measurement of deformation. Then, in the process of validating the developed modeling approach with the experimental residual stress data, manufacturing process simulations of the two simple structures are developed and undergo a formal verification and validation process, including a mesh

  1. Welding induced residual stress evaluation using laser-generated Rayleigh waves

    NASA Astrophysics Data System (ADS)

    Ye, Chong; Zhou, Yuanlai; Reddy, Vishnu V. B.; Mebane, Aaron; Ume, I. Charles

    2018-04-01

    Welding induced residual stress could affect the dimensional stability, fatigue life, and chemical resistance of the weld joints. Ultrasonic method serves as an important non-destructive tool for the residual stress evaluation due to its easy implementation, low cost and wide application to different materials. Residual stress would result in the ultrasonic wave velocity variation, which is the so called acoustoelastic effect. In this paper, Laser/EMAT ultrasonic technique was proposed to experimentally study the relative velocity variation ΔV/V of Rayleigh wave, which has the potential to evaluate surface/subsurface longitudinal residual stress developed during the Gas Metal Arc Welding process. Broad band ultrasonic waves were excited by pulsed Q-Switched Nd: YAG laser. An electromagnetic acoustic transducer (EMAT) attached to the welded plates was used to capture the Rayleigh wave signals propagating along the weld seam direction. Different time of flight measurements were conducted by varying the distance between the weld seam and Rayleigh wave propagating path in the range of 0 to 45 mm. The maximum relative velocity difference was found on the weld seam. With the increasing distance away from the weld seam, the relative velocity difference sharply decreased to negative value. With further increase in distance, the relative velocity difference slowly increased and approached zero. The distribution of relative velocity variations indicates that tensile stress appears in the melted zone as it becomes compressive near the heat-affected zone.

  2. Type I and type II residual stress in iron meteorites determined by neutron diffraction measurements

    NASA Astrophysics Data System (ADS)

    Caporali, Stefano; Pratesi, Giovanni; Kabra, Saurabh; Grazzi, Francesco

    2018-04-01

    In this work we present a preliminary investigation by means of neutron diffraction experiment to determine the residual stress state in three different iron meteorites (Chinga, Sikhote Alin and Nantan). Because of the very peculiar microstructural characteristic of this class of samples, all the systematic effects related to the measuring procedure - such as crystallite size and composition - were taken into account and a clear differentiation in the statistical distribution of residual stress in coarse and fine grained meteorites were highlighted. Moreover, the residual stress state was statistically analysed in three orthogonal directions finding evidence of the existence of both type I and type II residual stress components. Finally, the application of von Mises approach allowed to determine the distribution of type II stress.

  3. 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.

  4. Finite Element Analysis of Surface Residual Stress in Functionally Gradient Cemented Carbide Tool

    NASA Astrophysics Data System (ADS)

    Su, Chuangnan; Liu, Deshun; Tang, Siwen; Li, Pengnan; Qiu, Xinyi

    2018-03-01

    A component distribution model is proposed for three-component functionally gradient cemented carbide (FGCC) based on electron probe microanalysis results obtained for gradient layer thickness, microstructure, and elemental distribution. The residual surface stress of FGCC-T5 tools occurring during the fabrication process is analyzed using an ANSYS-implemented finite element method (FEM) and X-ray diffraction. A comparison of the experimental and calculated values verifies the feasibility of using FEM to analyze the residual surface stress in FGCC-T5 tools. The effects of the distribution index, geometrical shape, substrate thickness, gradient layer thickness, and position of the cobalt-rich layer on residual surface stress are studied in detail.

  5. 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.

  6. 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.

  7. Effect of residual stress on energy storage property in PbZrO3 antiferroelectric thin films with different orientations

    NASA Astrophysics Data System (ADS)

    Ge, Jun; Remiens, Denis; Costecalde, Jean; Chen, Ying; Dong, Xianlin; Wang, Genshui

    2013-10-01

    The effect of residual stress on energy storage property was investigated for a series of PbZrO3 thin films on SrTiO3 and Si substrates. Compressive or tensile residual stress influences the critical electric field EA for the ferroelectric-to-antiferroelectric phase transition, thus for films with (110)/(101) orientation, energy density W of films on SrTiO3 is 38% larger than films on Si; in contrast, (001)-oriented PbZrO3 films on SrTiO3 show slightly smaller W compared to films on Si. We conclude that the different responses of W to stress are related to the different constrain states in films with different orientations.

  8. Blanking Method with Aid of Scrap to Reduce Tensile Residual Stress on Sheared Edge

    NASA Astrophysics Data System (ADS)

    Yasutomi, T.; Yonemura, S.; Yoshida, T.; Mizumura, M.; Hiwatashi, S.

    2017-09-01

    A simple shearing method to reduce tensile residual stress on a sheared edge is highly desired in the automotive industry because this type of stress deteriorates the fatigue property of automotive parts. In this study, the effect of a coining method with a shearing scrap material on a sheared edge was investigated. The scrap part of a sheared plate has a fracture surface shape similar to that of the product part since these parts are generated by separation of a single plate with crack propagation. Therefore, it is possible to impose plastic strain over the entire fracture surface by using the scrap part as a coining tool. Effectiveness of this method was investigated for high-tensile-strength steel. Using this method, the tensile residual stress on the sheared surface was significantly reduced and work hardening was slightly increased. The effects of shearing clearance and coining stroke were also investigated. Tensile residual stress decreased as the coining stroke increased; however, it saturated at a certain stroke. The stroke at which tensile residual stress saturated was relatively small at a large clearance. In particular, the amount of plastic deformation on fracture surface increased when coining stroke became large. These tendencies could be explained by the conditions of contact, which were investigated using finite element analysis.

  9. 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.

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

    PubMed

    Ballestra, Alberto; Somà, Aurelio; Pavanello, Renato

    2008-02-06

    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.

  11. 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

  12. Investigation of the Effect of Residual Stress Gradient on the Wear Behavior of PVD Thin Films

    NASA Astrophysics Data System (ADS)

    Tlili, B.; Nouveau, C.; Guillemot, G.; Besnard, A.; Barkaoui, A.

    2018-02-01

    The control of residual stresses has been seldom investigated in multilayer coatings dedicated to improvement of wear behavior. Here, we report the preparation and characterization of superposed structures composed of Cr, CrN and CrAlN layers. Nano-multilayers CrN/CrAlN and Cr/CrN/CrAlN were deposited by Physical Vapor Deposition (PVD) onto Si (100) and AISI4140 steel substrates. The Cr, CrN and CrAlN monolayers were developed with an innovative approach in PVD coatings technologies corresponding to deposition with different residual stresses levels. Composition and wear tracks morphologies of the coatings were characterized by scanning electron microscopy, high-resolution transmission electron microscopy, atomic force microscopy, x-ray photoelectron spectroscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction and 3D-surface analyzer. The mechanical properties (hardness, residual stresses and wear) were investigated by nanoindentation, interferometry and micro-tribometry (fretting-wear tests). Observations suggest that multilayer coatings are composed mostly of nanocrystalline. The residual stresses level in the films has practically affected all the physicochemical and mechanical properties as well as the wear behavior. Consequently, it is demonstrated that the coating containing moderate stresses has a better wear behavior compared to the coating developed with higher residual stresses. The friction contact between coated samples and alumina balls shows also a large variety of wear mechanisms. In particular, the abrasive wear of the coatings was a combination of plastic deformation, fine microcracking and microspallation. The application of these multilayers will be wood machining of green wood.

  13. Influence of weld-induced residual stresses on the hysteretic behavior of a girth-welded circular stainless steel tube

    NASA Astrophysics Data System (ADS)

    Lee, Chin-Hyung; Nguyen Van Do, Vuong; Chang, Kyong-Ho; Jeon, Jun-Tai; Um, Tae-Hwan

    2018-04-01

    The present study attempts to characterize the relevance of welding residual stresses to the hysteretic behaviour of a girth-welded circular stainless steel tube under cyclic mechanical loadings. Finite element (FE) thermal simulation of the girth butt welding process is first performed to identify the weld-induced residual stresses by using the one-way coupled three-dimensional (3-D) thermo-mechanical FE analysis method. 3-D elastic-plastic FE analysis equipped with the cyclic plasticity constitutive model capable of describing the cyclic response is next carried out to scrutinize the effects that the residual stresses have on the hysteretic performance of the girth-welded steel tube exposed to cyclic axial loading, which takes the residual stresses and plastic strains calculated from the preceding thermo-mechanical analysis as the initial condition. The analytical results demonstrate that the residual stresses bring about premature yielding and deterioration of the load carrying capacity in the elastic and the transition load ranges, whilst the residual stress effect is wiped out quickly in the plastic load domain since the residual stresses are nearly wholly relaxed after application of the cyclic plastic loading.

  14. 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

  15. Through-Thickness Residual Stress Profiles in Austenitic Stainless Steel Welds: A Combined Experimental and Prediction Study

    NASA Astrophysics Data System (ADS)

    Mathew, J.; Moat, R. J.; Paddea, S.; Francis, J. A.; Fitzpatrick, M. E.; Bouchard, P. J.

    2017-12-01

    Economic and safe management of nuclear plant components relies on accurate prediction of welding-induced residual stresses. In this study, the distribution of residual stress through the thickness of austenitic stainless steel welds has been measured using neutron diffraction and the contour method. The measured data are used to validate residual stress profiles predicted by an artificial neural network approach (ANN) as a function of welding heat input and geometry. Maximum tensile stresses with magnitude close to the yield strength of the material were observed near the weld cap in both axial and hoop direction of the welds. Significant scatter of more than 200 MPa was found within the residual stress measurements at the weld center line and are associated with the geometry and welding conditions of individual weld passes. The ANN prediction is developed in an attempt to effectively quantify this phenomenon of `innate scatter' and to learn the non-linear patterns in the weld residual stress profiles. Furthermore, the efficacy of the ANN method for defining through-thickness residual stress profiles in welds for application in structural integrity assessments is evaluated.

  16. An analytical method on the surface residual stress for the cutting tool orientation

    NASA Astrophysics Data System (ADS)

    Li, Yueen; Zhao, Jun; Wang, Wei

    2010-03-01

    The residual stress is measured by choosing 8 kinds orientations on cutting the H13 dies steel on the HSM in the experiment of this paper. The measured data shows on that the residual stress exists periodicity for the different rake angle (β) and side rake angle (θ) parameters, further study find that the cutting tool orientations have closed relationship with the residual stresses, and for the original of the machined residual stress on the surface from the cutting force and the axial force, it can be gained the simply model of tool-workpiece force, using the model it can be deduced the residual stress model, which is feasible to calculate the size of residual stress. And for almost all the measured residual stresses are compressed stress, the compressed stress size and the direction could be confirmed by the input data for the H13 on HSM. As the result, the residual stress model is the key for optimization of rake angle (β) and side rake angle (θ) in theory, using the theory the more cutting mechanism can be expressed.

  17. Residual stress measurement of PMMA by combining drilling-hole with digital speckle correlation method

    NASA Astrophysics Data System (ADS)

    Yao, X. F.; Xiong, T. C.; Xu, H. M.; Wan, J. P.; Long, G. R.

    2008-11-01

    The residual stresses of the PMMA (polymethyl methacrylate) specimens after being drilled, reamed and polished respectively are investigated using the digital speckle correlation experimental method,. According to the displacement fields around the correlated calculated region, the polynomial curve fitting method is used to obtain the continuous displacement fields, and the strain fields can be obtained from the derivative of the displacement fields. Considering the constitutive equation of the material, the expression of the residual stress can be presented. During the data processing, according to the fitting effect of the data, the calculation region of the correlated speckles and the degree of the polynomial fitting curve is decided. These results show that the maximum stress is at the hole-wall of the drilling hole specimen and with the increasing of the diameter of the drilled hole, the residual stress resulting from the hole drilling increases, whereas the process of reaming and polishing hole can reduce the residual stress. The relative large discrete degree of the residual stress is due to the chip removal ability of the drill bit, the cutting feed of the drill and other various reasons.

  18. 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.

  19. Thermal stress effects in intermetallic matrix composites

    NASA Technical Reports Server (NTRS)

    Wright, P. K.; Sensmeier, M. D.; Kupperman, D. S.; Wadley, H. N. G.

    1993-01-01

    Intermetallic matrix composites develop residual stresses from the large thermal expansion mismatch (delta-alpha) between the fibers and matrix. This work was undertaken to: establish improved techniques to measure these thermal stresses in IMC's; determine residual stresses in a variety of IMC systems by experiments and modeling; and, determine the effect of residual stresses on selected mechanical properties of an IMC. X ray diffraction (XRD), neutron diffraction (ND), synchrotron XRD (SXRD), and ultrasonics (US) techniques for measuring thermal stresses in IMC were examined and ND was selected as the most promising technique. ND was demonstrated on a variety of IMC systems encompassing Ti- and Ni-base matrices, SiC, W, and Al2O3 fibers, and different fiber fractions (Vf). Experimental results on these systems agreed with predictions of a concentric cylinder model. In SiC/Ti-base systems, little yielding was found and stresses were controlled primarily by delta-alpha and Vf. In Ni-base matrix systems, yield strength of the matrix and Vf controlled stress levels. The longitudinal residual stresses in SCS-6/Ti-24Al-llNb composite were modified by thermomechanical processing. Increasing residual stress decreased ultimate tensile strength in agreement with model predictions. Fiber pushout strength showed an unexpected inverse correlation with residual stress. In-plane shear yield strength showed no dependence on residual stress. Higher levels of residual tension led to higher fatigue crack growth rates, as suggested by matrix mean stress effects.

  20. Optimization of the Mechanical Properties and Residual Stresses in 2024 Aluminum Alloy Through Heat Treatment

    NASA Astrophysics Data System (ADS)

    Araghchi, M.; Mansouri, H.; Vafaei, R.; Guo, Y.

    2018-05-01

    Residual stresses induced during quenching of aluminum alloys cause dimensional instability and distortion. In this study, the effects of different concentrations of polyalkylene glycol (PAG) quenchants on residual stresses and mechanical properties of 2024 aluminum alloy were investigated. Surface residual stresses were measured by using hole-drilling strain-gauge method. Also, mechanical properties and microstructure of the heat-treated samples were analyzed using hardness measurements, tensile tests, and transmission electron microscopy. Results showed that quenching into a 15% polymeric solution and aging at 190 °C for 12 h cause 50% reduction in residual stress as compared with quenching in water at 20 °C and naturally aging. Moreover, tensile strength decreased by 104 MPa ( 20%) in compared with the T6 sample.

  1. Effect of Turning and Ball Burnishing on the Microstructure and Residual Stress Distribution in Stainless Steel Cold Spray Deposits

    NASA Astrophysics Data System (ADS)

    Sova, A.; Courbon, C.; Valiorgue, F.; Rech, J.; Bertrand, Ph.

    2017-12-01

    In this paper, an experimental study of influence of machining by turning and ball burnishing on the surface morphology, structure and residual stress distribution of cold spray 17-4 PH stainless steel deposits is provided. It is shown that cold spray deposits could be machined by turning under parameters closed to turning of bulk 17-4 PH stainless steel. Ball burnishing process permits to decrease surface roughness. Cross-sectional observation revealed that the turning and ball burnishing process allowed microstructure changes in the coating near-surface zone. In particular, significant particle deformation and particle boundary fragmentation is observed. Measurements of residual stresses showed that residual stresses in the as-spray deposit are compressive. After machining by turning, tensile residual stresses in the near-surface zone were induced. Further surface finishing of turned coating by ball burnishing allowed the establishment of the compressive residual stresses in the coating.

  2. Evaluation of Residual Stress Measurements Before and After Post-Weld Heat Treatment in the Weld Repairs

    NASA Astrophysics Data System (ADS)

    Pardowska, Anna M.; Price, John W. H.; Finlayson, Trevor R.; Ibrahim, R.

    2010-11-01

    Welding repairs are increasingly a structural integrity concern for aging pressure vessel and piping components. It has been demonstrated that the residual stress distribution near repair welds can be drastically different from that of the original weld. Residual stresses have a significant effect on the lifetime performance of a weld, and a reduction of these stresses is normally desirable. The aim of this paper is to investigate residual stresses in various weld repair arrangements using the non-destructive neutron diffraction technique. This research is focused on characterization of the residual stress distribution: (i) in the original weld; (ii) in a shallow toe weld repair; and (iii) after conventional post-weld heat treatment. The focus of the measurements is on the values of the subsurface strain/stress variations across the weld.

  3. A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System.

    PubMed

    Song, Yan; Wu, Weijie; Xie, Feng; Liu, Yilun; Wang, Tiejun

    2017-01-01

    Residual stress arisen in fabrication process of Double-Ceramic-Layer Thermal Barrier Coating System (DCL-TBCs) has a significant effect on its quality and reliability. In this work, based on the practical fabrication process of DCL-TBCs and the force and moment equilibrium, a theoretical model was proposed at first to predict residual stress generation in its fabrication process, in which the temperature dependent material properties of DCL-TBCs were incorporated. Then, a Finite Element method (FEM) has been carried out to verify our theoretical model. Afterwards, some important geometric parameters for DCL-TBCs, such as the thickness ratio of stabilized Zirconia (YSZ, ZrO2-8%Y2O3) layer to Lanthanum Zirconate (LZ, La2Zr2O7) layer, which is adjustable in a wide range in the fabrication process, have a remarkable effect on its performance, therefore, the effect of this thickness ratio on residual stress generation in the fabrication process of DCL-TBCs has been systematically studied. In addition, some thermal spray treatment, such as the pre-heating treatment, its effect on residual stress generation has also been studied in this work. It is found that, the final residual stress mainly comes from the cooling down process in the fabrication of DCL-TBCs. Increasing the pre-heating temperature can obviously decrease the magnitude of residual stresses in LZ layer, YSZ layer and substrate. With the increase of the thickness ratio of YSZ layer to LZ layer, magnitudes of residual stresses arisen in LZ layer and YSZ layer will increase while residual stress in substrate will decrease.

  4. FIB-based measurement of local residual stresses on microsystems

    NASA Astrophysics Data System (ADS)

    Vogel, Dietmar; Sabate, Neus; Gollhardt, Astrid; Keller, Juergen; Auersperg, Juergen; Michel, Bernd

    2006-03-01

    The paper comprises research results obtained for stress determination on micro and nanotechnology components. It meets the concern of controlling stresses introduced to sensors, MEMS and electronics devices during different micromachining processes. The method bases on deformation measurement options made available inside focused ion beam equipment. Removing locally material by ion beam milling existing stresses / residual stresses lead to deformation fields around the milled feature. Digital image correlation techniques are used to extract deformation values from micrographs captured before and after milling. In the paper, two main milling features have been analyzed - through hole and through slit milling. Analytical solutions for stress release fields of in-plane stresses have been derived and compared to respective experimental findings. Their good agreement allows to settle a method for determination of residual stress values, which is demonstrated for thin membranes manufactured by silicon micro technology. Some emphasis is made on the elimination of main error sources for stress determination, like rigid body object displacements and rotations due to drifts of experimental conditions under FIB imaging. In order to illustrate potential application areas of the method residual stress suppression by ion implantation is evaluated by the method and reported here.

  5. 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.

  6. Evaluation of service-induced residual stresses in railroad commuter car wheels

    DOT National Transportation Integrated Search

    1999-11-01

    Analyses of the effects of service conditions on the distribution of : residual stresses in railroad commuter car wheels are presented. Novel : software has been applied to estimate the effects of service conditions : on the as-manufactured state of ...

  7. Residual stress evaluation by Barkhausen signals with a magnetic field sensor for high efficiency electrical motors

    NASA Astrophysics Data System (ADS)

    Tsuchida, Yuji; Enokizono, Masato

    2018-04-01

    The iron loss of industrial motors increases by residual stress during manufacturing processes. It is very important to make clear the distribution of the residual stress in the motor cores to reduce the iron loss in the motors. Barkhausen signals which occur on electrical steel sheets can be used for the evaluation of the residual stress because they are very sensitive to the material properties. Generally, a B-sensor is used to measure Barkhausen signals, however, we developed a new H-sensor to measure them and applied it into the stress evaluation. It is supposed that the Barkhausen signals by using a H-sensor can be much effective to the residual stress on the electrical steel sheets by referring our results regarding to the stress evaluations. We evaluated the tensile stress of the electrical steel sheets by measuring Barkhausen signals by using our developed H-sensor for high efficiency electrical motors.

  8. A study for high accuracy measurement of residual stress by deep hole drilling technique

    NASA Astrophysics Data System (ADS)

    Kitano, Houichi; Okano, Shigetaka; Mochizuki, Masahito

    2012-08-01

    The deep hole drilling technique (DHD) received much attention in recent years as a method for measuring through-thickness residual stresses. However, some accuracy problems occur when residual stress evaluation is performed by the DHD technique. One of the reasons is that the traditional DHD evaluation formula applies to the plane stress condition. The second is that the effects of the plastic deformation produced in the drilling process and the deformation produced in the trepanning process are ignored. In this study, a modified evaluation formula, which is applied to the plane strain condition, is proposed. In addition, a new procedure is proposed which can consider the effects of the deformation produced in the DHD process by investigating the effects in detail by finite element (FE) analysis. Then, the evaluation results obtained by the new procedure are compared with that obtained by traditional DHD procedure by FE analysis. As a result, the new procedure evaluates the residual stress fields better than the traditional DHD procedure when the measuring object is thick enough that the stress condition can be assumed as the plane strain condition as in the model used in this study.

  9. Viscoelastic finite element analysis of residual stresses in porcelain-veneered zirconia dental crowns.

    PubMed

    Kim, Jeongho; Dhital, Sukirti; Zhivago, Paul; Kaizer, Marina R; Zhang, Yu

    2018-06-01

    The main problem of porcelain-veneered zirconia (PVZ) dental restorations is chipping and delamination of veneering porcelain owing to the development of deleterious residual stresses during the cooling phase of veneer firing. The aim of this study is to elucidate the effects of cooling rate, thermal contraction coefficient and elastic modulus on residual stresses developed in PVZ dental crowns using viscoelastic finite element methods (VFEM). A three-dimensional VFEM model has been developed to predict residual stresses in PVZ structures using ABAQUS finite element software and user subroutines. First, the newly established model was validated with experimentally measured residual stress profiles using Vickers indentation on flat PVZ specimens. An excellent agreement between the model prediction and experimental data was found. Then, the model was used to predict residual stresses in more complex anatomically-correct crown systems. Two PVZ crown systems with different thermal contraction coefficients and porcelain moduli were studied: VM9/Y-TZP and LAVA/Y-TZP. A sequential dual-step finite element analysis was performed: heat transfer analysis and viscoelastic stress analysis. Controlled and bench convection cooling rates were simulated by applying different convective heat transfer coefficients 1.7E-5 W/mm 2 °C (controlled cooling) and 0.6E-4 W/mm 2 °C (bench cooling) on the crown surfaces exposed to the air. Rigorous viscoelastic finite element analysis revealed that controlled cooling results in lower maximum stresses in both veneer and core layers for the two PVZ systems relative to bench cooling. Better compatibility of thermal contraction coefficients between porcelain and zirconia and a lower porcelain modulus reduce residual stresses in both layers. Copyright © 2018 Elsevier Ltd. All rights reserved.

  10. Experimental Study of Residual Stresses in Rail by Moire Interferometry

    DOT National Transportation Integrated Search

    1993-09-01

    The residual stresses in rails produced by rolling cycles are studied experimentally by moire interferometry. The dissection technique is adopted for this investigation. The basic principle of the dissection technique is that the residual stress is r...

  11. 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.

  12. A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System

    PubMed Central

    Song, Yan; Wu, Weijie; Xie, Feng; Liu, Yilun; Wang, Tiejun

    2017-01-01

    Residual stress arisen in fabrication process of Double-Ceramic-Layer Thermal Barrier Coating System (DCL-TBCs) has a significant effect on its quality and reliability. In this work, based on the practical fabrication process of DCL-TBCs and the force and moment equilibrium, a theoretical model was proposed at first to predict residual stress generation in its fabrication process, in which the temperature dependent material properties of DCL-TBCs were incorporated. Then, a Finite Element method (FEM) has been carried out to verify our theoretical model. Afterwards, some important geometric parameters for DCL-TBCs, such as the thickness ratio of stabilized Zirconia (YSZ, ZrO2-8%Y2O3) layer to Lanthanum Zirconate (LZ, La2Zr2O7) layer, which is adjustable in a wide range in the fabrication process, have a remarkable effect on its performance, therefore, the effect of this thickness ratio on residual stress generation in the fabrication process of DCL-TBCs has been systematically studied. In addition, some thermal spray treatment, such as the pre-heating treatment, its effect on residual stress generation has also been studied in this work. It is found that, the final residual stress mainly comes from the cooling down process in the fabrication of DCL-TBCs. Increasing the pre-heating temperature can obviously decrease the magnitude of residual stresses in LZ layer, YSZ layer and substrate. With the increase of the thickness ratio of YSZ layer to LZ layer, magnitudes of residual stresses arisen in LZ layer and YSZ layer will increase while residual stress in substrate will decrease. PMID:28103275

  13. Measurement of non-uniform residual stresses by combined Moiré interferometry and hole-drilling method: Theory, experimental method and applications

    NASA Astrophysics Data System (ADS)

    Ya, Min; Dai, Fulong; Xie, Huimin; Lü, Jian

    2003-12-01

    Hole-drilling method is one of the most convenient methods for engineering residual stress measurement. Combined with moiré interferometry to obtain the relaxed whole-field displacement data, hole-drilling technique can be used to solve non-uniform residual stress problems, both in-depth and in-plane. In this paper, the theory of moiré interferometry and incremental hole-drilling (MIIHD) for non-uniform residual stress measurement is introduced. Three dimensional finite element model is constructed by ABAQUS to obtain the coefficients for the residual stress calculation. An experimental system including real-time measurement, automatic data processing and residual stresses calculation is established. Two applications for non-uniform in-depth residual stress of surface nanocrystalline material and non-uniform in-plane residual stress of friction stir welding are presented. Experimental results show that MIIHD is effective for both non-uniform in-depth and in-plane residual stress measurements.

  14. Redistribution of Welding Residual Stresses of Crack Tip Opening Displacement Specimen by Local Compression.

    PubMed

    Kim, Young-Gon; Song, Kuk-Hyun; Lee, Dong-Hoon; Joo, Sung-Min

    2018-03-01

    The demand of crack tip opening displacement (CTOD) test which evaluates fracture toughness of a cracked material is very important to ensure the stability of structure under severe service environment. The validity of the CTOD test result is judged using several criterions of the specification standards. One of them is the artificially generated fatigue pre-crack length inside the specimen. For acceptable CTOD test results, fatigue pre-crack must have a reasonable sharp crack front. The propagation of fatigue crack started from the tip of the machined notch, which might have propagated irregularly due to residual stress field. To overcome this problem, test codes suggest local compression method, reversed bending method and stepwise high-R ratio method to reduce the disparity of residual stress distribution inside the specimen. In this paper, the relation between the degree of local compression and distribution of welding residual stress has been analyzed by finite element analyses in order to determine the amount of effective local compression of the test piece. Analysis results show that initial welding residual stress is dramatically varied three-dimensionally while cutting, notch machining and local compressing due to the change of internal restraint force. From the simulation result, the authors find that there is an optimum amount of local compression to modify regularly for generating fatigue pre-crack propagation. In the case of 0.5% compressions of the model width is the most effective for uniforming residual stress distribution.

  15. Residual-stress measurement in socket welded joints by neutron diffraction

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Hayashi, M.; Ishiwata, M.; Minakawa, N.

    1994-12-31

    Neutron diffraction measurements of lattice strains provide spatial maps of residual stress near welds in ferritic steel socket joints. The highest tensile stresses in the welds are found in axial, radial and hoop direction at the weld root. However, the highest tensile stress in the axial direction is about 110MPa. Balancing compressive stresses are found near the surface of the socket weld fusion zone. Heat treatment at 600 C for 2 hours is sufficient to relieve residual stress in socket welds.

  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. Experimental Investigations to evaluate the effects of cutting parameters on cutting temperature and residual stresses during milling process of the AISI 1045

    NASA Astrophysics Data System (ADS)

    Abdelkrim, M.; Brabie, G.; Belloufi, A.; Catalin, T.; Chirita, B.

    2017-08-01

    Today major metal cutting companies in industrial countries, looking to gain time and reduce manufacturing costs while respecting the environment. There are many phenomena which affect the quality and production costs of the product, including cutting efforts, cutting temperature, residual stresses, etc. A better understanding of these phenomena will reduce production costs and maximize productivity. The aim of this work is to analyze the effect of machining conditions (cutting speed, feed speed and cutting depth) on cutting temperature and residual stresses, during the milling operations using the response surface method. A good accuracy between predicted and measured values of the cutting temperature was found, the cutting speed and the depth of cut are parameters whose effect is most sensitive to the residual stresses and the cutting temperature.However, little influence has been registered in the case of an increase of the feed rate. The percentage of error is 4.57%, indicating that the numerical approach can accurately predict the cutting temperature of the AISI 1045.

  18. Evolution of residual stress, free volume, and hardness in the laser shock peened Ti-based metallic glass

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Wang, Liang; Wang, Lu; Nie, Zhihua

    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.more » 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.« less

  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. 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

    2017-11-01

    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.

  1. Numerical simulation of residual stress in laser based additive manufacturing process

    NASA Astrophysics Data System (ADS)

    Kalyan Panda, Bibhu; Sahoo, Seshadev

    2018-03-01

    Minimizing the residual stress build-up in metal-based additive manufacturing plays a pivotal role in selecting a particular material and technique for making an industrial part. In beam-based additive manufacturing, although a great deal of effort has been made to minimize the residual stresses, it is still elusive how to do so by simply optimizing the processing parameters, such as beam size, beam power, and scan speed. Amid different types of additive manufacturing processes, Direct Metal Laser Sintering (DMLS) process uses a high-power laser to melt and sinter layers of metal powder. The rapid solidification and heat transfer on powder bed endows a high cooling rate which leads to the build-up of residual stresses, that will affect the mechanical properties of the build parts. In the present work, the authors develop a numerical thermo-mechanical model for the measurement of residual stress in the AlSi10Mg build samples by using finite element method. Transient temperature distribution in the powder bed was assessed using the coupled thermal to structural model. Subsequently, the residual stresses were estimated with varying laser power. From the simulation result, it found that the melt pool dimensions increase with increasing the laser power and the magnitude of residual stresses in the built part increases.

  2. 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.

  3. 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.

  4. Experimental Investigation of Principal Residual Stress and Fatigue Performance for Turned Nickel-Based Superalloy Inconel 718.

    PubMed

    Hua, Yang; Liu, Zhanqiang

    2018-05-24

    Residual stresses of turned Inconel 718 surface along its axial and circumferential directions affect the fatigue performance of machined components. However, it has not been clear that the axial and circumferential directions are the principle residual stress direction. The direction of the maximum principal residual stress is crucial for the machined component service life. The present work aims to focuses on determining the direction and magnitude of principal residual stress and investigating its influence on fatigue performance of turned Inconel 718. The turning experimental results show that the principal residual stress magnitude is much higher than surface residual stress. In addition, both the principal residual stress and surface residual stress increase significantly as the feed rate increases. The fatigue test results show that the direction of the maximum principal residual stress increased by 7.4%, while the fatigue life decreased by 39.4%. The maximum principal residual stress magnitude diminished by 17.9%, whereas the fatigue life increased by 83.6%. The maximum principal residual stress has a preponderant influence on fatigue performance as compared to the surface residual stress. The maximum principal residual stress can be considered as a prime indicator for evaluation of the residual stress influence on fatigue performance of turned Inconel 718.

  5. 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.

  6. Residual Stress Developed During the Cure of Thermosetting Polymers: Optimizing Cure Schedule to Minimize Stress.

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kropka, Jamie Michael; Stavig, Mark E.; Jaramillo, Rex

    When thermosetting polymers are used to bond or encapsulate electrical, mechanical or optical assemblies, residual stress, which often affects the performance and/or reliability of these devices, develops within the structure. The Thin-Disk-on-Cylinder structural response test is demonstrated as a powerful tool to design epoxy encapsulant cure schedules to reduce residual stress, even when all the details of the material evolution during cure are not explicitly known. The test's ability to (1) distinguish between cohesive and adhesive failure modes and (2) demonstrate methodologies to eliminate failure and reduce residual stress, make choices of cure schedules that optimize stress in the encapsulantmore » unambiguous. For the 828/DEA/GMB material in the Thin-Disk-on-Cylinder geometry, the stress associated with cure is significant and outweighs that associated with cool down from the final cure temperature to room temperature (for measured lid strain, Scure I > I I e+h erma * II) * The difference between the final cure temperature and 1 1 -- the temperature at which the material gels, Tf-T ge i, was demonstrated to be a primary factor in determining the residual stress associated with cure. Increasing T f -T ge i leads to a reduction in cure stress that is described as being associated with balancing some of the 828/DEA/GMB cure shrinkage with thermal expansion. The ability to tune residual stress associated with cure by controlling T f -T ge i would be anticipated to translate to other thermosetting encapsulation materials, but the times and temperatures appropriate for a given material may vary widely.« less

  7. Influence of Welding Strength Matching Coefficient and Cold Stretching on Welding Residual Stress in Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Lu, Yaqing; Hui, Hu; Gong, Jianguo

    2018-05-01

    Austenitic stainless steel is widely used in pressure vessels for the storage and transportation of liquid gases such as liquid nitrogen, liquid oxygen, and liquid hydrogen. Cryogenic pressure vessel manufacturing uses cold stretching technology, which relies heavily on welding joint performance, to construct lightweight and thin-walled vessels. Residual stress from welding is a primary factor in cases of austenitic stainless steel pressure vessel failure. In this paper, on the basis of Visual Environment 10.0 finite element simulation technology, the residual stress resulting from different welding strength matching coefficients (0.8, 1, 1.2, 1.4) for two S30408 plates welded with three-pass butt welds is calculated according to thermal elastoplastic theory. In addition, the stress field was calculated under a loading as high as 410 MPa and after the load was released. Path 1 was set to analyze stress along the welding line, and path 2 was set to analyze stress normal to the welding line. The welding strength matching coefficient strongly affected both the longitudinal residual stress (center of path 1) and the transverse residual stress (both ends of path 1) after the welding was completed. However, the coefficient had little effect on the longitudinal and transverse residual stress of path 2. Under the loading of 410 MPa, the longitudinal and transverse stress decreased and the stress distribution, with different welding strength matching coefficients, was less diverse. After the load was released, longitudinal and transverse stress distribution for both path 1 and path 2 decreased to a low level. Cold stretching could reduce the effect of residual stress to various degrees. Transverse strain along the stretching direction was also taken into consideration. The experimental results validated the reliability of the partial simulation.

  8. 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

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    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 straightmore » 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.« less

  10. Mechanical Characterization of Thermomechanical Matrix Residual Stresses Incurred During MMC Processing

    NASA Technical Reports Server (NTRS)

    Castelli, Michael G.

    1998-01-01

    In recent years, much effort has been spent examining the residual stress-strain states of advanced composites. Such examinations are motivated by a number of significant concerns that affect composite development, processing, and analysis. The room-temperature residual stress states incurred in many advanced composite systems are often quite large and can introduce damage even prior to the first external mechanical loading of the material. These stresses, which are induced during the cooldown following high-temperature consolidation, result from the coefficient of thermal expansion mismatch between the fiber and matrix. Experimental techniques commonly used to evaluate composite internal residual stress states are non-mechanical in nature and generally include forms of x-ray and neutron diffraction. Such approaches are usually complex, involving a number of assumptions and limitations associated with a wide range of issues, including the depth of penetration, the volume of material being assessed, and erroneous effects associated with oriented grains. Furthermore, and more important to the present research, these techniques can assess only "single time" stress in the composite. That is, little, if any, information is obtained that addresses the time-dependent point at which internal stresses begin to accumulate, the manner in which the accumulation occurs, and the presiding relationships between thermoelastic, thermoplastic, and thermoviscous behaviors. To address these critical issues, researchers at the NASA Lewis Research Center developed and implemented an innovative mechanical test technique to examine in real time, the time-dependent thermomechanical stress behavior of a matrix alloy as it went through a consolidation cycle.

  11. Determination of Residual Stresses in Rails

    DOT National Transportation Integrated Search

    1983-05-01

    A destructive sectioning technique for measuring the complete three-dimensional residual stresses in a rail cross section was developed. The technique was applied to four tangent rail specimens: two 136-pound specimens were taken from FAST (Facility ...

  12. Numerical and Experimental Study on the Residual Stresses in the Nitrided Steel

    NASA Astrophysics Data System (ADS)

    Song, X.; Zhang, Zhi-Qian; Narayanaswamy, S.; Huang, Y. Z.; Zarinejad, M.

    2016-09-01

    In the present work, residual stresses distribution in the gas nitrided AISI 4140 sample has been studied using finite element (FE) simulation. The nitrogen concentration profile is obtained from the diffusion-controlled compound layer growth model, and nitrogen concentration controls the material volume change through phase transformation and lattice interstitials which results in residual stresses. Such model is validated through residual stress measurement technique—micro-ring-core method, which is applied to the nitriding process to obtain the residual stresses profiles in both the compound and diffusion layer. The numerical and experimental results are in good agreement with each other; they both indicate significant stress variation in the compound layer, which was not captured in previous research works due to the resolution limit of the traditional methods.

  13. Residual stresses in passenger car wheels

    DOT National Transportation Integrated Search

    2006-11-05

    The purpose of this paper is to present the extension of previous studies aimed at understanding the residual stress distribution in as-manufactured railroad wheels. In order to address loading conditions which are not axially symmetric, a manufactur...

  14. The Influence of the Support Structure on Residual Stress and Distortion in SLM Inconel 718 Parts

    NASA Astrophysics Data System (ADS)

    Mishurova, Tatiana; Cabeza, Sandra; Thiede, Tobias; Nadammal, Naresh; Kromm, Arne; Klaus, Manuela; Genzel, Christoph; Haberland, Christoph; Bruno, Giovanni

    2018-07-01

    The effect of support structure and of removal from the base plate on the residual stress state in selective laser melted IN718 parts was studied by means of synchrotron X-ray diffraction. The residual stresses in subsurface region of two elongated prisms in as-built condition and after removal from the base plate were determined. One sample was directly built on a base plate and another one on a support structure. Also, the distortion on the top surface due to stress release was measured by contact profilometry. High tensile residual stress values were found, with pronounced stress gradient along the hatching direction. In the sample on support, stress redistribution took place after removal from the base plate, as opposed to simple stress relaxation for the sample without support. The sample on support structure showed larger distortion compared to sample without support. We conclude that the use of a support decreases stress values but stress-relieving heat treatments are still needed.

  15. The Influence of the Support Structure on Residual Stress and Distortion in SLM Inconel 718 Parts

    NASA Astrophysics Data System (ADS)

    Mishurova, Tatiana; Cabeza, Sandra; Thiede, Tobias; Nadammal, Naresh; Kromm, Arne; Klaus, Manuela; Genzel, Christoph; Haberland, Christoph; Bruno, Giovanni

    2018-05-01

    The effect of support structure and of removal from the base plate on the residual stress state in selective laser melted IN718 parts was studied by means of synchrotron X-ray diffraction. The residual stresses in subsurface region of two elongated prisms in as-built condition and after removal from the base plate were determined. One sample was directly built on a base plate and another one on a support structure. Also, the distortion on the top surface due to stress release was measured by contact profilometry. High tensile residual stress values were found, with pronounced stress gradient along the hatching direction. In the sample on support, stress redistribution took place after removal from the base plate, as opposed to simple stress relaxation for the sample without support. The sample on support structure showed larger distortion compared to sample without support. We conclude that the use of a support decreases stress values but stress-relieving heat treatments are still needed.

  16. 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.

  17. On the Rule of Mixtures for Predicting Stress-Softening and Residual Strain Effects in Biological Tissues and Biocompatible Materials.

    PubMed

    Elías-Zúñiga, Alex; Baylón, Karen; Ferrer, Inés; Serenó, Lídia; García-Romeu, Maria Luisa; Bagudanch, Isabel; Grabalosa, Jordi; Pérez-Recio, Tania; Martínez-Romero, Oscar; Ortega-Lara, Wendy; Elizalde, Luis Ernesto

    2014-01-16

    In this work, we use the rule of mixtures to develop an equivalent material model in which the total strain energy density is split into the isotropic part related to the matrix component and the anisotropic energy contribution related to the fiber effects. For the isotropic energy part, we select the amended non-Gaussian strain energy density model, while the energy fiber effects are added by considering the equivalent anisotropic volumetric fraction contribution, as well as the isotropized representation form of the eight-chain energy model that accounts for the material anisotropic effects. Furthermore, our proposed material model uses a phenomenological non-monotonous softening function that predicts stress softening effects and has an energy term, derived from the pseudo-elasticity theory, that accounts for residual strain deformations. The model's theoretical predictions are compared with experimental data collected from human vaginal tissues, mice skin, poly(glycolide-co-caprolactone) (PGC25 3-0) and polypropylene suture materials and tracheal and brain human tissues. In all cases examined here, our equivalent material model closely follows stress-softening and residual strain effects exhibited by experimental data.

  18. The interaction of fatigue cracks with a residual stress field using thermoelastic stress analysis and synchrotron X-ray diffraction experiments

    PubMed Central

    Amjad, Khurram; Asquith, David; Sebastian, Christopher M.; Wang, Wei-Chung

    2017-01-01

    This article presents an experimental study on the fatigue behaviour of cracks emanating from cold-expanded holes utilizing thermoelastic stress analysis (TSA) and synchrotron X-ray diffraction (SXRD) techniques with the aim of resolving the long-standing ambiguity in the literature regarding potential relaxation, or modification, of beneficial compressive residual stresses as a result of fatigue crack propagation. The crack growth rates are found to be substantially lower as the crack tip moved through the residual stress zone induced by cold expansion. The TSA results demonstrated that the crack tip plastic zones were reduced in size by the presence of the residual compressive stresses induced by cold expansion. The crack tip plastic zones were found to be insignificant in size in comparison to the residual stress zone resulting from cold expansion, which implied that they were unlikely to have had a notable impact on the surrounding residual stresses induced by cold expansion. The residual stress distributions measured along the direction of crack growth, using SXRD, showed no signs of any significant stress relaxation or redistribution, which validates the conclusions drawn from the TSA data. Fractographic analysis qualitatively confirmed the influence on crack initiation of the residual stresses induced by the cold expansion. It was found that the application of single compressive overload caused a relaxation, or reduction in the residual stresses, which has wider implications for improving the fatigue life. PMID:29291095

  19. The crack-contact and the free-end problem for a strip under residual stress

    NASA Technical Reports Server (NTRS)

    Bakioglu, M.; Erdogan, F.

    1977-01-01

    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 where 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's crossing the entire plate thickness, the problem becomes a stressfree end problem for a semiinfinite 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 semiinfinite strip are of special interest. For two typical residual-stress states the solution is obtained, and some numerical results are given.

  20. Distortion and Residual Stress Control in Integrally Stiffened Structure Produced by Direct Metal Deposition

    NASA Technical Reports Server (NTRS)

    Lin, Shih-Yung; Hoffman, Eric K.; Domack, Marcia S.

    2007-01-01

    2-D thermo-mechanical model developed to characterize distortion and residual stresses in integral structure produced by DMD. Demonstrated as a tool to guide experimental development of DMD fabrication process for aero structures. Distortion and residual stresses are local to deposit. Most distortion develops during deposition of the first few layers; Little change in distortion or residual stresses after fifth deposit layer Most of distortion is localized just beneath the build. Thicker build plates and the use of build lands results in greatest decrease in levels of distortion. Pre-straining shown to reduce distortion. Difficult to implement, particularly for complex stiffener arrays. Clamp position has complex effect on distortion and stresses. Overall distortion reduced with decreasing clamp clearance. Larger clamp clearances induce bending. Use of pre-heat and active cooling show minor influence on panel distortion. Generate changes in thermal gradients in the build plate.

  1. 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.

  2. Finite element estimation of the residual stresses in roller-straightened rail

    DOT National Transportation Integrated Search

    2004-11-13

    The purpose of this paper is to develop models to accurately predict : the residual stresses due to the roller straightening of railroad rails. : Several aspects of residual stress creation in rail due to roller : straightening are addressed. The eff...

  3. 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.

  4. 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.

  5. The influence of deformation-induced residual stresses on the post-forming tensile stress/strain behavior of dual-phase steels

    NASA Astrophysics Data System (ADS)

    Hance, Brandon Michael

    It was hypothesized that, in dual-phase (DP) steels, strain partitioning between ferrite (alpha) and martensite (alpha') during deformation results in a distribution of post-deformation residual stresses that, in turn, affects the subsequent strength, work hardening behavior and formability when the strain path is changed. The post-forming deformation-induced residual stress state was expected to depend upon the microstructure, the amount of strain and the prestrain path. The primary objective of this research program was to understand the influence of deformation-induced residual stresses on the post-forming tensile stress/strain behavior of DP steels. Three commercially produced sheet steels were considered in this analysis: (1) a DP steel with approximately 15 vol. % martensite, (2) a conventional high-strength, low-alloy (HSLA) steel, and (3) a conventional, ultra-low-carbon interstitial-free (IF) steel. Samples of each steel were subjected to various prestrain levels in various plane-stress forming modes, including uniaxial tension, plane strain and balanced biaxial stretching. Neutron diffraction experiments confirmed the presence of large post-forming deformation-induced residual stresses in the ferrite phase of the DP steel. The deformation-alphainduced residual stress state varied systematically with the prestrain mode, where the principal residual stress components are proportional to the principal strain components of the prestrain mode, but opposite in sign. For the first time, and by direct experimental correlation, it was shown that deformation-induced residual stresses greatly affect the post-forming tensile stress/strain behavior of DP steels. As previously reported in the literature, the formability (residual tensile ductility) of the IF steel and the HSLA steel was adversely affected by strain path changes. The DP steel presents a formability advantage over the conventional IF and HSLA steels, and is expected to be particularly well suited for

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Robinson, J.S., E-mail: jeremy.robinson@ul.ie; Redington, W.

    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,more » 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.« less

  7. 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

  8. Application of welding simulation to block joints in shipbuilding and assessment of welding-induced residual stresses and distortions

    NASA Astrophysics Data System (ADS)

    Fricke, Wolfgang; Zacke, Sonja

    2014-06-01

    During ship design, welding-induced distortions are roughly estimated as a function of the size of the component as well as the welding process and residual stresses are assumed to be locally in the range of the yield stress. Existing welding simulation methods are very complex and time-consuming and therefore not applicable to large structures like ships. Simplified methods for the estimation of welding effects were and still are subject of several research projects, but mostly concerning smaller structures. The main goal of this paper is the application of a multi-layer welding simulation to the block joint of a ship structure. When welding block joints, high constraints occur due to the ship structure which are assumed to result in accordingly high residual stresses. Constraints measured during construction were realized in a test plant for small-scale welding specimens in order to investigate their and other effects on the residual stresses. Associated welding simulations were successfully performed with fine-mesh finite element models. Further analyses showed that a courser mesh was also able to reproduce the welding-induced reaction forces and hence the residual stresses after some calibration. Based on the coarse modeling it was possible to perform the welding simulation at a block joint in order to investigate the influence of the resulting residual stresses on the behavior of the real structure, showing quite interesting stress distributions. Finally it is discussed whether smaller and idealized models of definite areas of the block joint can be used to achieve the same results offering possibilities to consider residual stresses in the design process.

  9. Nanoindentation data analysis of loading curve performed on DLC thin films: Effect of residual stress on the elasto-plastic properties

    NASA Astrophysics Data System (ADS)

    Ouchabane, M.; Dublanche-Tixier, Ch.; Dergham, D.

    2017-11-01

    The present work is a contribution to the understanding of the mechanical behavior of DLC thin films through nanoindentation tests. DLC films of different thicknesses deposited by the PECVD process on a silicon substrate contain high residual compressive stresses when they are very thin and the stresses become relatively low and more relaxed as the film thickens. These different levels of residual stress influence the values of hardness (H) and Young's modulus (E) obtained when probing the film-substrate system by nanoindentation. It is observed that the DLC layers exhibit different mechanical behaviors even when they are deposited under the same conditions. It is proposed that the compressive stress induces structural modifications resulting in modifying the elasto-plastic properties of each thin film-substrate system. Data analysis of the loading curve can provide information on the elasto-plastic properties of DLC thin films, particularly the stiffness (S) and Er2/H, as a function of residual compressive stresses. The structural changes induced by residual stresses were probed by using Raman spectroscopy and correlated to the mechanical properties.

  10. Residual stress analysis of welded joints by the variational eigenstrain approach

    NASA Astrophysics Data System (ADS)

    Korsunsky, Alexander M.; Regino, Gabriel; Nowell, David

    2005-04-01

    We present the formulation for finding the distribution of eigenstrains, i.e. the sources of residual stress, from a set of measurements of residual elastic strain (e.g. by diffraction), or residual stress, or stress redistribution, or distortion. The variational formulation employed seeks to achieve the best agreement between the model prediction and some measured parameters in the sense of a minimum of a functional given by a sum over the entire set of measurements. The advantage of this approach lies in its flexibility: different sets of measurements and information about different components of the stress-strain state can be incorporated. We demonstrate the power of the technique by analysing experimental data for welds in thin sheet of a nickel superalloy aerospace material. Very good agreement can be achieved between the prediction and the measurement results without the necessity of using iterative solution. In practice complete characterisation of residual stress states is often very difficult, due to limitations of facility access, measurement time or specimen dimensions. Implications of the new technique for experimental analysis are all the more significant, since it allows the reconstruction of the entire stress state from incomplete sets of data.

  11. 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.

  12. 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.

  13. X-ray diffraction analysis of residual stresses in textured ZnO thin films

    NASA Astrophysics Data System (ADS)

    Dobročka, E.; Novák, P.; Búc, D.; Harmatha, L.; Murín, J.

    2017-02-01

    Residual stresses are commonly generated in thin films during the deposition process and can influence the film properties. Among a number of techniques developed for stress analysis, X-ray diffraction methods, especially the grazing incidence set-up, are of special importance due to their capability to analyze the stresses in very thin layers as well as to investigate the depth variation of the stresses. In this contribution a method combining multiple {hkl} and multiple χ modes of X-ray diffraction stress analysis in grazing incidence set-up is used for the measurement of residual stress in strongly textured ZnO thin films. The method improves the precision of the stress evaluation in textured samples. Because the measurements are performed at very low incidence angles, the effect of refraction of X-rays on the measured stress is analyzed in details for the general case of non-coplanar geometry. It is shown that this effect cannot be neglected if the angle of incidence approaches the critical angle. The X-ray stress factors are calculated for hexagonal fiber-textured ZnO for the Reuss model of grain-interaction and the effect of texture on the stress factors is analyzed. The texture in the layer is modelled by Gaussian distribution function. Numerical results indicate that in the process of stress evaluation the Reuss model can be replaced by much simpler crystallite group method if the standard deviation of Gaussian describing the texture is less than 6°. The results can be adapted for fiber-textured films of various hexagonal materials.

  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. Long-Term Stability of Residual Stress Improvement by Water Jet Peening Considering Working Processes.

    PubMed

    Hashimoto, Tadafumi; Osawa, Yusuke; Itoh, Shinsuke; Mochizuki, Masahito; Nishimoto, Kazutoshi

    2013-06-01

    To prevent primary water stress corrosion cracking (PWSCC), water jet peening (WJP) has been used on the welds of Ni-based alloys in pressurized water reactors (PWRs). Before WJP, the welds are machined and buffed in order to conduct a penetrant test (PT) to verify the weld qualities to access, and microstructure evolution takes place in the target area due to the severe plastic deformation. The compressive residual stresses induced by WJP might be unstable under elevated temperatures because of the high dislocation density in the compressive stress layer. Therefore, the stability of the compressive residual stresses caused by WJP was investigated during long-term operation by considering the microstructure evolution due to the working processes. The following conclusions were made: The compressive residual stresses were slightly relaxed in the surface layers of the thermally aged specimens. There were no differences in the magnitude of the relaxation based on temperature or time. The compressive residual stresses induced by WJP were confirmed to remain stable under elevated temperatures. The stress relaxation at the surface followed the Johnson-Mehl equation, which states that stress relaxation can occur due to the recovery of severe plastic strain, since the estimated activation energy agrees very well with the self-diffusion energy for Ni. By utilizing the additivity rule, it was indicated that stress relaxation due to recovery is completed during the startup process. It was proposed that the long-term stability of WJP under elevated temperatures must be assessed based on compressive stresses with respect to the yield stress. Thermal elastic-plastic creep analysis was performed to predict the effect of creep strain. After 100 yr of simulated continuous operation at 80% capacity, there was little change in the WJP compressive stresses under an actual operating temperature of 623 K. Therefore, the long-term stability of WJP during actual operation was

  16. Effect of laser welding process on the microstructure, mechanical properties and residual stresses in Ti-5Al-2.5Sn alloy

    NASA Astrophysics Data System (ADS)

    Junaid, Massab; Khan, Fahd Nawaz; Rahman, Khalid; Baig, Mirza Nadeem

    2017-12-01

    Pulsed Nd-YAG laser was employed in bead on plate configuration for welding of 1.6 mm thick Ti-5Al-2.5Sn alloy sheet. The effect of laser processing parameters on the weld pool shape, pulse overlap, oxide formation, and microstructure were studied using scanning electron and optical microscope. It was found out that laser peak power had a significant influence on the FZ oxygen contents and grain size whereas, both peak power and heat input per unit length were important in defining the weld pool shape. Processing parameters for full penetration welds with acceptable joint properties and low oxygen contents were selected for further study in terms of residual stresses and mechanical properties. Formation of acicular α and α‧ martensite in fusion and heat affected zone, led to an increase in microhardness by about 55 HV0.2 as compared to base metal. Induced residual stresses were found to be significantly less than the yield strength resulting in plate deformation less than 1 mm. Transverse residual stresses present at different depths below the surface tend to counter effect each other resulting in tensile strength of welded specimen becoming nearly equal to that of the base metal.

  17. 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

  18. 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.

  19. On the Rule of Mixtures for Predicting Stress-Softening and Residual Strain Effects in Biological Tissues and Biocompatible Materials

    PubMed Central

    Elías-Zúñiga, Alex; Baylón, Karen; Ferrer, Inés; Serenó, Lídia; Garcia-Romeu, Maria Luisa; Bagudanch, Isabel; Grabalosa, Jordi; Pérez-Recio, Tania; Martínez-Romero, Oscar; Ortega-Lara, Wendy; Elizalde, Luis Ernesto

    2014-01-01

    In this work, we use the rule of mixtures to develop an equivalent material model in which the total strain energy density is split into the isotropic part related to the matrix component and the anisotropic energy contribution related to the fiber effects. For the isotropic energy part, we select the amended non-Gaussian strain energy density model, while the energy fiber effects are added by considering the equivalent anisotropic volumetric fraction contribution, as well as the isotropized representation form of the eight-chain energy model that accounts for the material anisotropic effects. Furthermore, our proposed material model uses a phenomenological non-monotonous softening function that predicts stress softening effects and has an energy term, derived from the pseudo-elasticity theory, that accounts for residual strain deformations. The model’s theoretical predictions are compared with experimental data collected from human vaginal tissues, mice skin, poly(glycolide-co-caprolactone) (PGC25 3-0) and polypropylene suture materials and tracheal and brain human tissues. In all cases examined here, our equivalent material model closely follows stress-softening and residual strain effects exhibited by experimental data. PMID:28788466

  20. Numerical simulation on residual stress in Y-slit type cracking test of Q690E

    NASA Astrophysics Data System (ADS)

    Huang, Wenjian; Lin, Guozhen; Chen, Zhanglan; Chen, Wu

    2018-03-01

    Numerical simulation on residual stress in Y-slit type cracking test of Q690E is carried out by using ANSYS. First, the dynamic distribution of welding temperature field is calculated; second, the results of the temperature field are converted into corresponding stress by the method of indirect coupling. The testing results show that the longitudinal residual stress of the weld is greater than the transverse residual stress and the peak of transverse residual stress is on the weld groove.

  1. 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.

  2. A quantitative non-destructive residual stress assessment tool for pipelines.

    DOT National Transportation Integrated Search

    2014-09-01

    G2MT successfully demonstrated the eStress system, a powerful new nondestructive evaluation : system for analyzing through-thickness residual stresses in mechanical damaged areas of steel : pipelines. The eStress system is designed to help pipe...

  3. The Effect of Heat Treatment on Residual Stress and Machining Distortions in Advanced Nickel Base Disk Alloys

    NASA Technical Reports Server (NTRS)

    Gayda, John

    2001-01-01

    This paper describes an extension of NASA's AST and IDPAT Programs which sought to predict the effect of stabilization heat treatments on residual stress and subsequent machining distortions in the advanced disk alloy, ME-209. Simple "pancake" forgings of ME-209 were produced and given four heat treats: 2075F(SUBSOLVUS)/OIL QUENCH/NO AGE; 2075F/OIL QUENCH/1400F@8HR;2075F/OIL QUENCH/1550F@3HR/l400F@8HR; and 2160F(SUPERSOLVUS)/OIL QUENCH/1550F@3HR/ 1400F@8HR. The forgings were then measured to obtain surface profiles in the heat treated condition. A simple machining plan consisting of face cuts from the top surface followed by measurements of the surface profile opposite the cut were made. This data provided warpage maps which were compared with analytical results. The analysis followed the IDPAT methodology and utilized a 2-D axisymmetric, viscoplastic FEA code. The analytical results accurately tracked the experimental data for each of the four heat treatments. The 1550F stabilization heat treatment was found to significantly reduce residual stresses and subsequent machining distortions for fine grain (subsolvus) ME209, while coarse grain (supersolvus) ME209 would require additional time or higher stabilization temperatures to attain the same degree of stress relief.

  4. 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.

  5. Assessment of the Local Residual Stresses of 7050-T7452 Aluminum Alloy in Microzones by the Instrumented Indentation with the Berkovich Indenter

    NASA Astrophysics Data System (ADS)

    He, M.; Huang, C. H.; Wang, X. X.; Yang, F.; Zhang, N.; Li, F. G.

    2017-10-01

    The local residual stresses in microzones are investigated by the instrumented indentation method with the Berkovich indenter. The parameters required for determination of residual stresses are obtained from indentation load-penetration depth curves constructed during instrumented indentation tests on flat square 7050-T7452 aluminum alloy specimens with a central hole containing the compressive residual stresses generated by the cold extrusion process. The force balance system with account of the tensile and compressive residual stresses is used to explain the phenomenon of different contact areas produced by the same indentation load. The effect of strain-hardening exponent on the residual stress is tuned-off by application of the representative stress σ_{0.033} in the average contact pressure assessment using the Π theorem, while the yield stress value is obtained from the constitutive function. Finally, the residual stresses are calculated according to the proposed equations of the force balance system, and their feasibility is corroborated by the XRD measurements.

  6. Burst Ductility of Zirconium Clads: The Defining Role of Residual Stress

    NASA Astrophysics Data System (ADS)

    Kumar, Gulshan; Kanjarla, A. K.; Lodh, Arijit; Singh, Jaiveer; Singh, Ramesh; Srivastava, D.; Dey, G. K.; Saibaba, N.; Doherty, R. D.; Samajdar, Indradev

    2016-08-01

    Closed end burst tests, using room temperature water as pressurizing medium, were performed on a number of industrially produced zirconium (Zr) clads. A total of 31 samples were selected based on observed differences in burst ductility. The latter was represented as total circumferential elongation or TCE. The selected samples, with a range of TCE values (5 to 35 pct), did not show any correlation with mechanical properties along axial direction, microstructural parameters, crystallographic textures, and outer tube-surface normal ( σ 11) and shear ( τ 13) components of the residual stress matrix. TCEs, however, had a clear correlation with hydrostatic residual stress ( P h), as estimated from tri-axial stress analysis on the outer tube surface. Estimated P h also scaled with measured normal stress ( σ 33) at the tube cross section. An elastic-plastic finite element model with ductile damage failure criterion was developed to understand the burst mechanism of zirconium clads. Experimentally measured P h gradients were imposed on a solid element continuum finite element (FE) simulation to mimic the residual stresses present prior to pressurization. Trends in experimental TCEs were also brought out with computationally efficient shell element-based FE simulations imposing the outer tube-surface P h values. Suitable components of the residual stress matrix thus determined the burst performance of the Zr clads.

  7. 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.

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

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

    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

  10. Numerical sensitivity analysis of welding-induced residual stress depending on variations in continuous cooling transformation behavior

    NASA Astrophysics Data System (ADS)

    Heinze, C.; Schwenk, C.; Rethmeier, M.; Caron, J.

    2011-06-01

    The usage of continuous cooling transformation (CCT) diagrams in numerical welding simulations is state of the art. Nevertheless, specifications provide limits in chemical composition of materials which result in different CCT behavior and CCT diagrams, respectively. Therefore, it is necessary to analyze the influence of variations in CCT diagrams on the developing residual stresses. In the present paper, four CCT diagrams and their effect on numerical calculation of residual stresses are investigated for the widely used structural steel S355J2 + N welded by the gas metal arc welding (GMAW) process. Rather than performing an arbitrary adjustment of CCT behavior, four justifiable data sets were used as input to the numerical calculation: data available in the Sysweld database, experimental data acquired through Gleeble dilatometry tests, and TTT/CCT predictions calculated from the JMatPro and Edison Welding Institute (EWI) Virtual Joining Portal software. The performed numerical analyses resulted in noticeable deviations in residual stresses considering the different CCT diagrams. Furthermore, possibilities to improve the prediction of distortions and residual stress based on CCT behavior are discussed.

  11. Effect of heat input on the microstructure, residual stresses and corrosion resistance of 304L austenitic stainless steel weldments

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Unnikrishnan, Rahul, E-mail: rahulunnikrishnannair@gmail.com; Idury, K.S.N. Satish, E-mail: satishidury@gmail.com; Ismail, T.P., E-mail: tpisma@gmail.com

    Austenitic stainless steels are widely used in high performance pressure vessels, nuclear, chemical, process and medical industry due to their very good corrosion resistance and superior mechanical properties. However, austenitic stainless steels are prone to sensitization when subjected to higher temperatures (673 K to 1173 K) during the manufacturing process (e.g. welding) and/or certain applications (e.g. pressure vessels). During sensitization, chromium in the matrix precipitates out as carbides and intermetallic compounds (sigma, chi and Laves phases) decreasing the corrosion resistance and mechanical properties. In the present investigation, 304L austenitic stainless steel was subjected to different heat inputs by shielded metalmore » arc welding process using a standard 308L electrode. The microstructural developments were characterized by using optical microscopy and electron backscattered diffraction, while the residual stresses were measured by X-ray diffraction using the sin{sup 2}ψ method. It was observed that even at the highest heat input, shielded metal arc welding process does not result in significant precipitation of carbides or intermetallic phases. The ferrite content and grain size increased with increase in heat input. The grain size variation in the fusion zone/heat affected zone was not effectively captured by optical microscopy. This study shows that electron backscattered diffraction is necessary to bring out changes in the grain size quantitatively in the fusion zone/heat affected zone as it can consider twin boundaries as a part of grain in the calculation of grain size. The residual stresses were compressive in nature for the lowest heat input, while they were tensile at the highest heat input near the weld bead. The significant feature of the welded region and the base metal was the presence of a very strong texture. The texture in the heat affected zone was almost random. - Highlights: • Effect of heat input on microstructure

  12. The Effects of Boron Doping on Residual Stress of Hfcvd Diamond Film for Mems Applications

    NASA Astrophysics Data System (ADS)

    Zhao, Tianqi; Wang, Xinchang; Sun, Fanghong

    In this study, the residual stress of boron-doped diamond (BDD) films is investigated as a function of boron doping level using X-ray diffraction (XRD) analysis. Boron doping level is controlled from 1000ppm to 9000ppm by dissolving trimethyl borate into acetone. BDD films are deposited on silicon wafers using a bias-enhanced hot filament chemical vapor deposition (BE-HFCVD) system. Residual stress calculated by sin2 ψ method varies linearly from -2.4GPa to -1.1GPa with increasing boron doping level. On the BDD film of -1.75GPa, free standing BDD cantilevers are fabricated by photolithography and ICP-RIE processes, then tested by laser Doppler vibrometer (LDV). A cantilever with resonant frequency of 183KHz and Q factor of 261 in the air is fabricated.

  13. 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.

  14. 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

  15. Three-dimensional welding residual stresses evaluation based on the eigenstrain methodology via X-ray measurements at the surface

    NASA Astrophysics Data System (ADS)

    Ogawa, Masaru

    2014-12-01

    In order to assure structural integrity for operating welded structures, it is necessary to evaluate crack growth rate and crack propagation direction for each observed crack non-destructively. Here, three dimensional (3D) welding residual stresses must be evaluated to predict crack propagation. Today, X-ray diffraction is used and the ultrasonic method has been proposed as non-destructive method to measure residual stresses. However, it is impossible to determine residual stress distributions in the thickness direction. Although residual stresses through a depth of several tens of millimeters can be evaluated non-destructively by neutron diffraction, it cannot be used as an on-site measurement technique. This is because neutron diffraction is only available in special irradiation facilities. Author pays attention to the bead flush method based on the eigenstrain methodology. In this method, 3D welding residual stresses are calculated by an elastic Finite Element Method (FEM) analysis from eigenstrains which are evaluated by an inverse analysis from released strains by strain gauges in the removal of the reinforcement of the weld. Here, the removal of the excess metal can be regarded as non-destructive treatment because toe of weld which may become crack starters can be eliminated. The effectiveness of the method has been proven for welded plates and pipes even with relatively lower bead height. In actual measurements, stress evaluation accuracy becomes poorer because measured values of strain gauges are affected by processing strains on the machined surface. In the previous studies, the author has developed the bead flush method that is free from the influence of the affecting strains by using residual strains on surface by X-ray diffraction. However, stress evaluation accuracy is not good enough because of relatively poor measurement accuracy of X-ray diffraction. In this study, a method to improve the estimation accuracy of residual stresses in this method is

  16. Properties of the Residual Stress of the Temporally Filtered Navier-Stokes Equations

    NASA Technical Reports Server (NTRS)

    Pruett, C. D.; Gatski, T. B.; Grosch, C. E.; Thacker, W. D.

    2002-01-01

    The development of a unifying framework among direct numerical simulations, large-eddy simulations, and statistically averaged formulations of the Navier-Stokes equations, is of current interest. Toward that goal, the properties of the residual (subgrid-scale) stress of the temporally filtered Navier-Stokes equations are carefully examined. Causal time-domain filters, parameterized by a temporal filter width 0 less than Delta less than infinity, are considered. For several reasons, the differential forms of such filters are preferred to their corresponding integral forms; among these, storage requirements for differential forms are typically much less than for integral forms and, for some filters, are independent of Delta. The behavior of the residual stress in the limits of both vanishing and in infinite filter widths is examined. It is shown analytically that, in the limit Delta to 0, the residual stress vanishes, in which case the Navier-Stokes equations are recovered from the temporally filtered equations. Alternately, in the limit Delta to infinity, the residual stress is equivalent to the long-time averaged stress, and the Reynolds-averaged Navier-Stokes equations are recovered from the temporally filtered equations. The predicted behavior at the asymptotic limits of filter width is further validated by numerical simulations of the temporally filtered forced, viscous Burger's equation. Finally, finite filter widths are also considered, and a priori analyses of temporal similarity and temporal approximate deconvolution models of the residual stress are conducted.

  17. An analytical model to predict and minimize the residual stress of laser cladding process

    NASA Astrophysics Data System (ADS)

    Tamanna, N.; Crouch, R.; Kabir, I. R.; Naher, S.

    2018-02-01

    Laser cladding is one of the advanced thermal techniques used to repair or modify the surface properties of high-value components such as tools, military and aerospace parts. Unfortunately, tensile residual stresses generate in the thermally treated area of this process. This work focuses on to investigate the key factors for the formation of tensile residual stress and how to minimize it in the clad when using dissimilar substrate and clad materials. To predict the tensile residual stress, a one-dimensional analytical model has been adopted. Four cladding materials (Al2O3, TiC, TiO2, ZrO2) on the H13 tool steel substrate and a range of preheating temperatures of the substrate, from 300 to 1200 K, have been investigated. Thermal strain and Young's modulus are found to be the key factors of formation of tensile residual stresses. Additionally, it is found that using a preheating temperature of the substrate immediately before laser cladding showed the reduction of residual stress.

  18. Correlation Between the Microstructural Defects and Residual Stress in a Single Crystal Nickel-Based Superalloy During Different Creep Stages

    NASA Astrophysics Data System (ADS)

    Mo, Fangjie; Wu, Erdong; Zhang, Changsheng; Wang, Hong; Zhong, Zhengye; Zhang, Jian; Chen, Bo; Hofmann, Michael; Gan, Weimin; Sun, Guangai

    2018-03-01

    The present work attempts to reveal the correlation between the microstructural defects and residual stress in the single crystal nickel-based superalloy, both of which play the significant role on properties and performance. Neutron diffraction was employed to investigate the microstructural defects and residual stresses in a single crystal (SC) nickel-based superalloy, which was subjected to creeping under 220 MPa and 1000 °C for different times. The measured superlattice and fundamental lattice reflections confirm that the mismatch and tetragonal distortions with c/a > 1 exist in the SC superalloy. At the initially unstrained state, there exists the angular distortion between γ and γ' phases with small triaxial compressive stresses, ensuring the structural stability of the superalloy. After creeping, the tetragonal distortion for the γ phase is larger than that for the γ' phase. With increasing the creeping time, the mismatch between γ and γ' phases increases to the maximum, then decreases gradually and finally remains unchanged. The macroscopic residual stress shows a similar behavior with the mismatch, indicating the correlation between them. Based on the model of shear and dislocations, the evolution of microstructural defects and residual stress are reasonably explained. The effect of shear is dominant at the primary creep stage, which greatly enlarges the mismatch and the residual stress. The dislocations weaken the effect of shear for the further creep stage, resulting in the decrease of the mismatch and relaxation of the residual stress. Those findings add some helpful understanding into the microstructure-performance relationship in the SC nickel-based superalloy, which might provide the insight to materials design and applications.

  19. Bi-Metallic Composite Structures With Designed Internal Residual Stress Field

    NASA Technical Reports Server (NTRS)

    Brice, Craig A.

    2014-01-01

    Shape memory alloys (SMA) have a unique ability to recover small amounts of plastic strain through a temperature induced phase change. For these materials, mechanical displacement can be accomplished by heating the structure to induce a phase change, through which some of the plastic strain previously introduced to the structure can be reversed. This paper introduces a concept whereby an SMA phase is incorporated into a conventional alloy matrix in a co-continuous reticulated arrangement forming a bi-metallic composite structure. Through memory activation of the mechanically constrained SMA phase, a controlled residual stress field is developed in the interior of the structure. The presented experimental data show that the memory activation of the SMA composite component significantly changes the residual stress distribution in the overall structure. Designing the structural arrangement of the two phases to produce a controlled residual stress field could be used to create structures that have much improved durability and damage tolerance properties.

  20. Study on residual stresses in ultrasonic torsional vibration assisted micro-milling

    NASA Astrophysics Data System (ADS)

    Lu, Zesheng; Hu, Haijun; Sun, Yazhou; Sun, Qing

    2010-10-01

    It is well known that machining induced residual stresses can seriously affect the dimensional accuracy, corrosion and wear resistance, etc., and further influence the longevity and reliability of Micro-Optical Components (MOC). In Ultrasonic Torsional Vibration Assisted Micro-milling (UTVAM), cutting parameters, vibration parameters, mill cutter parameters, the status of wear length of tool flank are the main factors which affect residual stresses. A 2D model of UTVAM was established with FE analysis software ABAQUS. Johnson-Cook's flow stress model and shear failure principle are used as the workpiece material model and failure principle, while friction between tool and workpiece uses modified Coulomb's law whose sliding friction area is combined with sticking friction. By means of FEA, the influence rules of cutting parameters, vibration parameters, mill cutter parameters, the status of wear length of tool flank on residual stresses are obtained, which provides a basis for choosing optimal process parameters and improving the longevity and reliability of MOC.

  1. 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.

  2. Complexity in modeling of residual stresses and strains during polymerization of bone cement: effects of conversion, constraint, heat transfer, and viscoelastic property changes.

    PubMed

    Gilbert, Jeremy L

    2006-12-15

    Aseptic loosening of cemented joint prostheses remains a significant concern in orthopedic biomaterials. One possible contributor to cement loosening is the development of porosity, residual stresses, and local fracture of the cement that may arise from the in-situ polymerization of the cement. In-situ polymerization of acrylic bone cement is a complex set of interacting processes that involve polymerization reactions, heat generation and transfer, full or partial mechanical constraint, evolution of conversion- and temperature-dependent viscoelastic material properties, and thermal and conversion-driven changes in the density of the cement. Interactions between heat transfer and polymerization can lead to polymerization fronts moving through the material. Density changes during polymerization can, in the presence of mechanical constraint, lead to the development of locally high residual strain energy and residual stresses. This study models the interactions during bone cement polymerization and determines how residual stresses develop in cement and incorporates temperature and conversion-dependent viscoelastic behavior. The results show that the presence of polymerization fronts in bone cement result in locally high residual strain energies. A novel heredity integral approach is presented to track residual stresses incorporating conversion and temperature dependent material property changes. Finally, the relative contribution of thermal- and conversion-dependent strains to residual stresses is evaluated and it is found that the conversion-based strains are the major contributor to the overall behavior. This framework provides the basis for understanding the complex development of residual stresses and can be used as the basis for developing more complex models of cement behavior.

  3. Residual stress measurement in veneering ceramic by hole-drilling.

    PubMed

    Mainjot, Amélie K; Schajer, Gary S; Vanheusden, Alain J; Sadoun, Michaël J

    2011-05-01

    Mismatch in thermal expansion properties between veneering ceramic and metallic or high-strength ceramic cores can induce residual stresses and initiate cracks when combined with functional stresses. Knowledge of the stress distribution within the veneering ceramic is a key factor for understanding and predicting chipping failures, which are well-known problems with Yttria-tetragonal-zirconia-polycrystal based fixed partial dentures. The objectives of this study are to develop a method for measuring the stress profile in veneering ceramics and to compare ceramic-fused-to-metal compounds to veneered Yttria-tetragonal-zirconia-polycrystal ceramic. The hole-drilling method, often used for engineering measurements, was adapted for use with veneering ceramic. Because of the high sensitivity needed in comparison with industrial applications, a high sensitivity electrical measurement chain was developed. All samples exhibited the same type of stress vs. depth profile, starting with compressive at the ceramic surface, decreasing with depth and becoming tensile at 0.5-1.0mm from the surface, and then becoming slightly compressive again. The zirconia samples exhibited a stress depth profile of larger magnitude. The hole drilling method was shown be a practical tool for measuring residual stresses in veneering ceramics. Copyright © 2010 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  4. Understanding of the development of in-plane residual stress in sol-gel-derived metal oxide thin films

    NASA Astrophysics Data System (ADS)

    Ohno, Kentaro; Uchiyama, Hiroaki; Kozuka, Hiromitsu

    2012-01-01

    The in-plane residual stress in thin films greatly affects their properties and functionality as well as the substrate bending, and hence is an important factor to be controlled. In order to obtain general knowledge on the development of residual stress in sol-gel-derived oxide thin films, the in-plane residual stress was measured for yttria stabilized zirconia gel films on Si(100) wafers as a function of firing temperature by measuring the substrate curvature. The films showed a rather complex variation in residual stress, and the mechanism of the residual stress evolution was discussed, referencing the intrinsic stress and the x-ray diffraction data. At low annealing temperatures of 100-200 °C, the residual tensile stress decreased and became compressive partially due to the structural relaxation occurring during cooling. When the firing temperature was increased over 200 °C, the residual stress turned tensile, and increased with increasing annealing temperature, which was attributed to the increase in intrinsic stress due to film densification as well as to the reduced structural relaxation due to the progress of densification. The residual tensile stress slightly decreased at firing temperatures of 500-600 °C, which was attributed to the reduction in intrinsic stress due to thermally activated atomic diffusion as well as to emergence of thermal stress. At firing temperature over 600 °C, the residual tensile stress increased again, which was attributed to the increase in thermal stress generated during cooling due to the increased Young's modulus of the film. Although appearing to be complicated, the whole variation of residual stress with firing temperature could be understood in terms of film densification, structural relaxation, atomic diffusion, progress of crystallization and thermal strain. The illustration presented in the work may provide a clear insight on how the residual stress could be developed in a variety of functional sol

  5. Fatigue Life Variability in Large Aluminum Forgings with Residual Stress

    DTIC Science & Technology

    2011-07-01

    been conducted. A detailed finite element analysis of the forge/ quench /coldwork/machine process was performed in order to predict the bulk residual...forge/ quench /coldwork/machine process was performed in order to predict the bulk residual stresses in a fictitious aluminum bulkhead. The residual...continues to develop the capability for computational simulation of the forge, quench , cold work and machining processes. In order to handle the

  6. Residual stress and damage-induced critical fracture on CO2 laser treated fused silica

    NASA Astrophysics Data System (ADS)

    Matthews, M. J.; Stolken, J. S.; Vignes, R. M.; Norton, M. A.; Yang, S.; Cooke, J. D.; Guss, G. M.; Adams, J. J.

    2009-10-01

    Localized damage repair and polishing of silica-based optics using mid- and far-IR CO2 lasers has been shown to be an effective method for increasing optical damage threshold in the UV. However, it is known that CO2 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 we present the results of 351 nm, 3ns Gaussian damage growth experiments within regions of varying residual stress caused by prior CO2 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 1~40s square pulse CO2 laser exposures created over 0.5-1.25kW/cm2 with a 1-3mm 1/e2 diameter beam (Tmax~1500-3000K), 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 Tmax>=2000K. The effect of cooling rate on fictive temperature caused by CO2 laser heating are consistent with finite element calculations based on a Tool-Narayanaswamy relaxation model.

  7. Residual thermal stresses in a solid sphere cast from a thermosetting material

    NASA Technical Reports Server (NTRS)

    Levitsky, M.; Shaffer, B. W.

    1975-01-01

    Expressions are developed for the residual thermal stresses in a solid sphere cast from a chemically hardening thermosetting material in a rigid spherical mold. The description of the heat generation rate and temperature variation is derived from a first-order chemical reaction. Solidification is described by the continuous transformation of the material from an inviscid liquidlike state into an elastic solid, with intermediate properties determined by the degree of chemical reaction. Residual stress components are obtained as functions of the parameters of the hardening process and the properties of the hardening material. Variation of the residual stresses with a nondimensionalized reaction rate parameter and the relative compressibility of the hardened material is discussed in detail.

  8. 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.

  9. Residual Stresses in SAVY 4000 and Hagan Container Bodies

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Stroud, Mary Ann; Hill, Mary Ann; Tokash, Justin Charles

    Chloride-induced stress corrosion cracking (SCC) has been investigated as a potential failure mechanism for the SAVY 4000 and the Hagan containers used to store plutonium-bearing materials at Los Alamos National Laboratory. This report discusses the regions of the container bodies most susceptible to SCC and the magnitude of the residual stresses in those regions. Boiling MgCl2 testing indicated that for both containers the region near the top weld was most susceptible to SCC. The Hagan showed through wall cracking after 22-24 hours of exposure both parallel (axial stresses) and perpendicular (hoop stresses) to the weld. The SAVY 4000 container showedmore » significant cracking above and below the weld after 47 hours of exposure but there was no visual evidence of a through wall crack and the cracks did not leak water. Two through wall holes formed in the bottom of the SAVY 4000 container after 44-46 hours of exposure. For both containers, average “through wall” residual stresses were determined from hole drilling data 4 mm below the weld. In the Hagan body, average tensile hoop stresses were 194 MPa and average compressive axial stresses were -120 MPa. In the SAVY 4000 body, average compressive hoop stresses were 11 MPa and average tensile axial stresses were 25 MPa. Results suggest that because the Hagan container exhibited through wall cracking in a shorter time in boiling MgCl2 and had the higher average tensile stress, 194 MPa hoop stress, it is more susceptible to SCC than the SAVY 4000 container.« less

  10. Finite element analysis of residual stress in cold expanded plate with different thickness and expansion ratio

    NASA Astrophysics Data System (ADS)

    Arifin Shariffudin, Kamarul; Karuppanan, Saravanan; Patil, Santosh S.

    2017-10-01

    Cold expansion of fastener/rivet holes is a common way to generate beneficial compressive residual stress around the fastener hole. In this study, cold expansion process was simulated by finite-element method in order to determine the residual stress field around two cold expanded holes by varying the plate thickness and expansion ratio of the hole. The model was developed in ANSYS and assigned to aluminium alloy 7475-T61 material model. The results showed that the residual stress become more compressive as the plate thickness is increased up to t/d = 2.6 and decreased for further level of thickness. In addition, the residual stress at the edge of the hole become more compressive as the expansion ratio is increased up to 4.5% and decreased for further level of expansion. This study also found that the residual stresses near the entrance and the exit face of the plate are less compressive than the residual stresses on the mid-thickness of the plate.

  11. Surface Finish and Residual Stresses Induced by Orthogonal Dry Machining of AA7075-T651

    PubMed Central

    Jomaa, Walid; Songmene, Victor; Bocher, Philippe

    2014-01-01

    The surface finish was extensively studied in usual machining processes (turning, milling, and drilling). For these processes, the surface finish is strongly influenced by the cutting feed and the tool nose radius. However, a basic understanding of tool/surface finish interaction and residual stress generation has been lacking. This paper aims to investigate the surface finish and residual stresses under the orthogonal cutting since it can provide this information by avoiding the effect of the tool nose radius. The orthogonal machining of AA7075-T651 alloy through a series of cutting experiments was performed under dry conditions. Surface finish was studied using height and amplitude distribution roughness parameters. SEM and EDS were used to analyze surface damage and built-up edge (BUE) formation. An analysis of the surface topography showed that the surface roughness was sensitive to changes in cutting parameters. It was found that the formation of BUE and the interaction between the tool edge and the iron-rich intermetallic particles play a determinant role in controlling the surface finish during dry orthogonal machining of the AA7075-T651 alloy. Hoop stress was predominantly compressive on the surface and tended to be tensile with increased cutting speed. The reverse occurred for the surface axial stress. The smaller the cutting feed, the greater is the effect of cutting speed on both axial and hoop stresses. By controlling the cutting speed and feed, it is possible to generate a benchmark residual stress state and good surface finish using dry machining. PMID:28788534

  12. Advantages of Residual Stresses in Dynamically Riveted Joints.

    DTIC Science & Technology

    1978-02-01

    strain distribution around a rivet hole, and describes an experimental method for measuring the radial velocity of an expanding rivet. The advantages of... benefits of compressive residual stresses in riveted joints, fatigue specimens made of 2024-T81 aluminum were used. The specimens were tested at constant...concentration of in-service tensile stresses near the hole surfaze. Substan;Aal and significant benefits in design life and structural weight can be

  13. Measurement of the residual stress distribution in a thick pre-stretched aluminum plate

    NASA Astrophysics Data System (ADS)

    Yuan, S. X.; Li, X. Q.; M, S.; Zhang, Y. C.; Gong, Y. D.

    2008-12-01

    Thick pre-stretched aluminum alloy plates are widely used in aircraft, while machining distortion caused by initial residual stress release in thick plates is a common and serious problem. To reduce the distortion, the residual stress distribution in thick plate must be measured. According to the characteristics of the thick pre-stretched aluminum alloy plate, based the elastic mechanical theory, this article deduces the modified layer-removal strain method adapting two different strain situations, which are caused by tensile and compressive stress. To validate this method, the residual stresses distribution along the thick direction of plate 2D70T351 is measured by this method, it is shown that the new method deduced in this paper is simple and accurate, and is very useful in engineering.

  14. A unified momentum equation approach for computing thermal residual stresses during melting and solidification

    NASA Astrophysics Data System (ADS)

    Yeo, Haram; Ki, Hyungson

    2018-03-01

    In this article, we present a novel numerical method for computing thermal residual stresses from a viewpoint of fluid-structure interaction (FSI). In a thermal processing of a material, residual stresses are developed as the material undergoes melting and solidification, and liquid, solid, and a mixture of liquid and solid (or mushy state) coexist and interact with each other during the process. In order to accurately account for the stress development during phase changes, we derived a unified momentum equation from the momentum equations of incompressible fluids and elastoplastic solids. In this approach, the whole fluid-structure system is treated as a single continuum, and the interaction between fluid and solid phases across the mushy zone is naturally taken into account in a monolithic way. For thermal analysis, an enthalpy-based method was employed. As a numerical example, a two-dimensional laser heating problem was considered, where a carbon steel sheet was heated by a Gaussian laser beam. Momentum and energy equations were discretized on a uniform Cartesian grid in a finite volume framework, and temperature-dependent material properties were used. The austenite-martensite phase transformation of carbon steel was also considered. In this study, the effects of solid strains, fluid flow, mushy zone size, and laser heating time on residual stress formation were investigated.

  15. 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 k α1 . By introducing a photon energy screening technology, the monochromatic X-ray diffraction of tungsten k α1 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.

  16. Influences of Processing and Fatigue Cycling on Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

    NASA Astrophysics Data System (ADS)

    Gabb, T. P.; Rogers, R. B.; Nesbitt, J. A.; Miller, R. A.; Puleo, B. J.; Johnson, D.; Telesman, J.; Draper, S. L.; Locci, I. E.

    2017-11-01

    Oxidation and corrosion can attack superalloy disk surfaces exposed to increasing operating temperatures in some turbine engine environments. Any potential protective coatings must also be resistant to harmful fatigue cracking during service. The objective of this study was to investigate how residual stresses evolve in one such coating. Fatigue specimens of a powder metallurgy-processed disk superalloy were coated with a NiCrY coating, shot peened, and then subjected to fatigue in air at room and high temperatures. The effects of this processing and fatigue cycling on axial residual stresses and other aspects of the coating were assessed. While shot peening did induce beneficial compressive residual stresses in the coating and substrate, these stresses relaxed in the coating with subsequent heating. Several cast alloys having compositions near the coating were subjected to thermal expansion and tensile stress relaxation tests to help explain this response of residual stresses in the coating. For the coated fatigue specimens, this response contributed to earlier cracking of the coating than for the uncoated surface during long intervals of cycling at 760 °C. Yet, substantial compressive residual stresses still remained in the substrate adjacent to the coating, which were sufficient to suppress fatigue cracking there. The coating continued to protect the substrate from hot corrosion pitting, even after fatigue cracks initiated in the coating.

  17. Residual stress investigation of via-last through-silicon via by polarized Raman spectroscopy measurement and finite element simulation

    NASA Astrophysics Data System (ADS)

    Feng, Wei; Watanabe, Naoya; Shimamoto, Haruo; Aoyagi, Masahiro; Kikuchi, Katsuya

    2018-07-01

    The residual stresses induced around through-silicon vias (TSVs) by a fabrication process is one of the major concerns of reliability. We proposed a methodology to investigate the residual stress in a via-last TSV. Firstly, radial and axial thermal stresses were measured by polarized Raman spectroscopy. The agreement between the simulated stress level and measured results validated the detail simulation model. Furthermore, the validated simulation model was adopted to the study of residual stress by element death/birth methods. The residual stress at room temperature concentrates at passivation layers owing to the high fabrication process temperatures of 420 °C for SiN film and 350 °C for SiO2 films. For a Si substrate, a high-level stress was observed near potential device locations, which requires attention to address reliability concerns in stress-sensitive devices. This methodology of residual stress analysis can be adopted to investigate the residual stress in other devices.

  18. 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.

  19. Effects of thermal cycling parameters on residual stresses in alumina scales of CoNiCrAlY and NiCoCrAlY bond coats

    DOE PAGES

    Nordhorn, Christian; Mücke, Robert; Unocic, Kinga A.; ...

    2014-08-20

    In this paper, furnace cycling experiments were performed on free-standing high-velocity oxygen-fuel bond coat samples to investigate the effect of material composition, surface texture, and cycling conditions on the average stresses in the formed oxide scales after cooling. The oxide scale thicknesses were determined by SEM image analyses and information about the stresses were acquired by photo-stimulated luminescence-spectroscopy. Additionally, the scale thickness dependent stress fields were calculated in finite-element analyses including approximation functions for the surface roughness derived on the basis of profilometry data. The evolution of the average residual stress as a function of oxide scale thickness was subjectmore » to stochastic fluctuations predominantly caused by local scale spallations. In comparison to the supplemental modeling results, thermal stresses due to mismatch of thermal expansion coefficients are identified as the main contribution to the residual stresses. Finally, the theoretical results emphasize that analyses of spectroscopic data acquired for average stress investigations of alumina scales rely on detailed information about microstructural features.« less

  20. Study of residual stresses in CT test specimens welded by electron beam

    NASA Astrophysics Data System (ADS)

    Papushkin, I. V.; Kaisheva, D.; Bokuchava, G. D.; Angelov, V.; Petrov, P.

    2018-03-01

    The paper reports result of residual stress distribution studies in CT specimens reconstituted by electron beam welding (EBW). The main aim of the study is evaluation of the applicability of the welding technique for CT specimens’ reconstitution. Thus, the temperature distribution during electron beam welding of a CT specimen was calculated using Green’s functions and the residual stress distribution was determined experimentally using neutron diffraction. Time-of-flight neutron diffraction experiments were performed on a Fourier stress diffractometer at the IBR-2 fast pulsed reactor in FLNP JINR (Dubna, Russia). The neutron diffraction data estimates yielded a maximal stress level of ±180 MPa in the welded joint.

  1. Effects of damage and thermal residual stresses on the overall elastoplastic behavior of particle-reinforced metal matrix composites

    NASA Astrophysics Data System (ADS)

    Liu, Haitao

    The objective of the present study is to investigate damage mechanisms and thermal residual stresses of composites, and to establish the frameworks to model the particle-reinforced metal matrix composites with particle-matrix interfacial debonding, particle cracking or thermal residual stresses. An evolutionary interfacial debonding model is proposed for the composites with spheroidal particles. The construction of the equivalent stiffness is based on the fact that when debonding occurs in a certain direction, the load-transfer ability will lose in that direction. By using this equivalent method, the interfacial debonding problem can be converted into a composite problem with perfectly bonded inclusions. Considering the interfacial debonding is a progressive process in which the debonding area increases in proportion to external loading, a progressive interfacial debonding model is proposed. In this model, the relation between external loading and the debonding area is established using a normal stress controlled debonding criterion. Furthermore, an equivalent orthotropic stiffness tensor is constructed based on the debonding areas. This model is able to study the composites with randomly distributed spherical particles. The double-inclusion theory is recalled to model the particle cracking problems. Cracks inside particles are treated as penny-shape particles with zero stiffness. The disturbed stress field due to the existence of a double-inclusion is expressed explicitly. Finally, a thermal mismatch eigenstrain is introduced to simulate the inconsistent expansions of the matrix and the particles due to the difference of the coefficients of thermal expansion. Micromechanical stress and strain fields are calculated due to the combination of applied external loads and the prescribed thermal mismatch eigenstrains. For all of the above models, ensemble-volume averaging procedures are employed to derive the effective yield function of the composites. Numerical

  2. Finite Element Simulation of Shot Peening: Prediction of Residual Stresses and Surface Roughness

    NASA Astrophysics Data System (ADS)

    Gariépy, Alexandre; Perron, Claude; Bocher, Philippe; Lévesque, Martin

    Shot peening is a surface treatment that consists of bombarding a ductile surface with numerous small and hard particles. Each impact creates localized plastic strains that permanently stretch the surface. Since the underlying material constrains this stretching, compressive residual stresses are generated near the surface. This process is commonly used in the automotive and aerospace industries to improve fatigue life. Finite element analyses can be used to predict residual stress profiles and surface roughness created by shot peening. This study investigates further the parameters and capabilities of a random impact model by evaluating the representative volume element and the calculated stress distribution. Using an isotropic-kinematic hardening constitutive law to describe the behaviour of AA2024-T351 aluminium alloy, promising results were achieved in terms of residual stresses.

  3. Effect of Welding Processes on the Microstructure, Mechanical Properties and Residual Stresses of Plain 9Cr-1Mo Steel Weld Joints

    NASA Astrophysics Data System (ADS)

    Nagaraju, S.; Vasantharaja, P.; Brahadees, G.; Vasudevan, M.; Mahadevan, S.

    2017-12-01

    9Cr-1Mo steel designated as P9 is widely used in the construction of power plants and high-temperature applications. It is chosen for fabricating hexcan fuel subassembly wrapper components of fast breeder reactors. Arc welding processes are generally used for fabricating 9Cr-1Mo steel weld joints. A-TIG welding process is increasingly being adopted by the industries. In the present study, shielded metal arc (SMA), tungsten inert gas (TIG) and A-TIG welding processes are used for fabricating the 9Cr-1Mo steel weld joints of 10 mm thickness. Effect of the above welding processes on the microstructure evolution, mechanical properties and residual stresses of the weld joints has been studied in detail. All the three weld joints exhibited comparable strength and ductility values. 9Cr-1Mo steel weld joint fabricated by SMAW process exhibited lower impact toughness values caused by coarser grain size and inclusions. 9Cr-1Mo steel weld joint fabricated by TIG welding exhibited higher toughness due to finer grain size, while the weld joint fabricated by A-TIG welding process exhibited adequate toughness values. SMA steel weld joint exhibited compressive residual stresses in the weld metal and HAZ, while TIG and A-TIG weld joint exhibited tensile residual stresses in the weld metal and HAZ.

  4. 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.

  5. Scanning electron acoustic microscopy of indentation-induced cracks and residual stresses in ceramics

    NASA Technical Reports Server (NTRS)

    Cantrell, John H.; Qian, Menglu; Ravichandran, M. V.; Knowles, K. M.

    1990-01-01

    The ability of scanning electron acoustic microscopy (SEAM) to characterize ceramic materials is assessed. SEAM images of Vickers indentations in SiC whisker-reinforced alumina clearly reveal not only the radial cracks, the length of which can be used to estimate the fracture toughness of the material, but also reveal strong contrast, interpreted as arising from the combined effects of lateral cracks and the residual stress field left in the SiC whisker-reinforced alumina by the indenter. The strong contrast is removed after the material is heat treated at 1000 C to relieve the residual stresses around the indentations. A comparison of these observations with SEAM and reflected polarized light observations of Vickers indentations in soda-lime glass both before and after heat treatment confirms the interpretation of the strong contrast.

  6. Determination of Multiple Near-Surface Residual Stress Components in Laser Peened Aluminum Alloy via the Contour Method

    NASA Astrophysics Data System (ADS)

    Toparli, M. Burak; Fitzpatrick, Michael E.; Gungor, Salih

    2015-09-01

    In this study, residual stress fields, including the near-surface residual stresses, were determined for an Al7050-T7451 sample after laser peening. The contour method was applied to measure one component of the residual stress, and the relaxed stresses on the cut surfaces were then measured by X-ray diffraction. This allowed calculation of the three orthogonal stress components using the superposition principle. The near-surface results were validated with results from incremental hole drilling and conventional X-ray diffraction. The results demonstrate that multiple residual stress components can be determined using a combination of the contour method and another technique. If the measured stress components are congruent with the principal stress axes in the sample, then this allows for determination of the complete stress tensor.

  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. 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

  9. 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.

  10. Optimization of residual stresses in MMC's through the variation of interfacial layer architectures and processing parameters

    NASA Technical Reports Server (NTRS)

    Pindera, Marek-Jerzy; Salzar, Robert S.

    1996-01-01

    The objective of this work was the development of efficient, user-friendly computer codes for optimizing fabrication-induced residual stresses in metal matrix composites through the use of homogeneous and heterogeneous interfacial layer architectures and processing parameter variation. To satisfy this objective, three major computer codes have been developed and delivered to the NASA-Lewis Research Center, namely MCCM, OPTCOMP, and OPTCOMP2. MCCM is a general research-oriented code for investigating the effects of microstructural details, such as layered morphology of SCS-6 SiC fibers and multiple homogeneous interfacial layers, on the inelastic response of unidirectional metal matrix composites under axisymmetric thermomechanical loading. OPTCOMP and OPTCOMP2 combine the major analysis module resident in MCCM with a commercially-available optimization algorithm and are driven by user-friendly interfaces which facilitate input data construction and program execution. OPTCOMP enables the user to identify those dimensions, geometric arrangements and thermoelastoplastic properties of homogeneous interfacial layers that minimize thermal residual stresses for the specified set of constraints. OPTCOMP2 provides additional flexibility in the residual stress optimization through variation of the processing parameters (time, temperature, external pressure and axial load) as well as the microstructure of the interfacial region which is treated as a heterogeneous two-phase composite. Overviews of the capabilities of these codes are provided together with a summary of results that addresses the effects of various microstructural details of the fiber, interfacial layers and matrix region on the optimization of fabrication-induced residual stresses in metal matrix composites.

  11. Strengthening, Crack Arrest And Multiple Cracking In Brittle Materials Using Residual Stresses.

    DOEpatents

    Green, David J.; Sglavo, Vincenzo M.; Tandon, Rajan

    2003-02-11

    Embodiments include a method for forming a glass which displays visible cracking prior to failure when subjected to predetermined stress level that is greater than a predetermined minimum stress level and less than a failure stress level. The method includes determining a critical flaw size in the glass and introducing a residual stress profile to the glass so that a plurality of visible cracks are formed prior to failure when the glass is subjected to a stress that is greater than the minimum stress level and lower than the critical stress. One method for forming the residual stress profile includes performing a first ion exchange so that a first plurality of ions of a first element in the glass are exchanged with a second plurality of ions of a second element that have a larger volume than the first ions. A second ion exchange is also performed so that a plurality of the second ions in the glass are exchanged back to ions of the first element.

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

    NASA Astrophysics Data System (ADS)

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

    2007-05-01

    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.

  13. Influence of residual stress on the adhesion and surface morphology of PECVD-coated polypropylene

    NASA Astrophysics Data System (ADS)

    Jaritz, Montgomery; Hopmann, Christian; Behm, Henrik; Kirchheim, Dennis; Wilski, Stefan; Grochla, Dario; Banko, Lars; Ludwig, Alfred; Böke, Marc; Winter, Jörg; Bahre, Hendrik; Dahlmann, Rainer

    2017-11-01

    The properties of plasma-enhanced chemical vapour deposition (PECVD) coatings on polymer materials depend to some extent on the surface and material properties of the substrate. Here, isotactic polypropylene (PP) substrates are coated with silicon oxide (SiO x ) films. Plasmas for the deposition of SiO x are energetic and oxidative due to the high amount of oxygen in the gas mixture. Residual stress measurements using single Si cantilever stress sensors showed that these coatings contain high compressive stress. To investigate the influence of the plasma and the coatings, residual stress, silicon organic (SiOCH) coatings with different thicknesses between the PP and the SiO x coating are used as a means to protect the substrate from the oxidative SiO x coating process. Pull-off tests are performed to analyse differences in the adhesion of these coating systems. It could be shown that the adhesion of the PECVD coatings on PP depends on the coatings’ residual stress. In a PP/SiOCH/SiO x -multilayer system the residual stress can be significantly reduced by increasing the thickness of the SiOCH coating, resulting in enhanced adhesion.

  14. Experimental 3-D residual stress measurement in rails with thermal annealing

    DOT National Transportation Integrated Search

    1999-07-01

    This report describes a novel method to determine residual stresses in railroad rails. The method uses thermal annealing to relieve the internal stresses in rail slices while advanced techniques (Miore and Twyman/Green interferometry) are applied to ...

  15. 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.

  16. Estimation of residual stresses in railroad commuter car wheels following manufacture

    DOT National Transportation Integrated Search

    2003-06-01

    A computer simulation of the manufacturing process of railroad car wheels is described to determine the residual stresses in the wheel following fabrication. Knowledge of, and the ability to predict, these stresses is useful in assessing the ability ...

  17. Neutron residual stress measurements on rail sections for different production conditions

    DOT National Transportation Integrated Search

    2004-11-13

    Rail sectioning with subsequent neutron diffraction experiments has been used to assess residual stresses in the rails. In this study we present the results of neutron stress : measurements performed at the NIST Center for Neutron Research (NCNR) on ...

  18. Residual-stress-induced grain growth of twinned grains and its effect on formability of magnesium alloy sheet at room temperature

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kim, Se-Jong; Kim, Daeyong, E-mail: daeyong@kims.re.kr; Lee, Keunho

    2015-11-15

    A magnesium alloy sheet was subjected to in-plane compression along with a vertical load to avoid buckling during compression. Pre-compressed specimens machined from the sheet were annealed at different temperatures and the changes in microstructure and texture were observed using electron back scattered diffraction (EBSD). Twinned grains preferentially grew during annealing at 300 °C, so that a strong texture with the < 0001 > direction parallel to the transverse direction developed. EBSD analysis confirmed that the friction caused by the vertical load induced inhomogeneous distribution of residual stress, which acted as an additional driving force for preferential grain growth ofmore » twinned grain during annealing. The annealed specimen showed excellent formability. - Highlights: • A magnesium alloy sheet subjected to in-plane compression under a vertical load • The vertical load induced inhomogeneous distribution of the residual stress. • The residual stress acted as an additional driving force for grain growth. • The annealed specimen with strong non-basal texture showed excellent formability.« less

  19. Effects of Residual Stress, Axial Stretch, and Circumferential Shrinkage on Coronary Plaque Stress and Strain Calculations: A Modeling Study Using IVUS-Based Near-Idealized Geometries

    PubMed Central

    Wang, Liang; Zhu, Jian; Samady, Habib; Monoly, David; Zheng, Jie; Guo, Xiaoya; Maehara, Akiko; Yang, Chun; Ma, Genshan; Mintz, Gary S.; Tang, Dalin

    2017-01-01

    Accurate stress and strain calculations are important for plaque progression and vulnerability assessment. Models based on in vivo data often need to form geometries with zero-stress/strain conditions. The goal of this paper is to use IVUS-based near-idealized geometries and introduce a three-step model construction process to include residual stress, axial shrinkage, and circumferential shrinkage and investigate their impacts on stress and strain calculations. In Vivo intravascular ultrasound (IVUS) data of human coronary were acquired for model construction. In Vivo IVUS movie data were acquired and used to determine patient-specific material parameter values. A three-step modeling procedure was used to make our model: (a) wrap the zero-stress vessel sector to obtain the residual stress; (b) stretch the vessel axially to its length in vivo; and (c) pressurize the vessel to recover its in vivo geometry. Eight models were constructed for our investigation. Wrapping led to reduced lumen and cap stress and increased out boundary stress. The model with axial stretch, circumferential shrink, but no wrapping overestimated lumen and cap stress by 182% and 448%, respectively. The model with wrapping, circumferential shrink, but no axial stretch predicted average lumen stress and cap stress as 0.76 kPa and −15 kPa. The same model with 10% axial stretch had 42.53 kPa lumen stress and 29.0 kPa cap stress, respectively. Skipping circumferential shrinkage leads to overexpansion of the vessel and incorrect stress/strain calculations. Vessel stiffness increase (100%) leads to 75% lumen stress increase and 102% cap stress increase. PMID:27814429

  20. Immediate and residual effects of heat stress and restricted intake on milk protein and casein composition and energy metabolism.

    PubMed

    Cowley, F C; Barber, D G; Houlihan, A V; Poppi, D P

    2015-04-01

    The effects of heat stress on dairy production can be separated into 2 distinct causes: those effects that are mediated by the reduced voluntary feed intake associated with heat stress, and the direct physiological and metabolic effects of heat stress. To distinguish between these, and identify their effect on milk protein and casein concentration, mid-lactation Holstein-Friesian cows (n = 24) were housed in temperature-controlled chambers and either subjected to heat stress [HS; temperature-humidity index (THI) ~78] or kept in a THI<70 environment and pair-fed with heat-stressed cows (TN-R) for 7 d. A control group of cows was kept in a THI<70 environment with ad libitum feeding (TN-AL). A subsequent recovery period (7 d), with THI<70 and ad libitum feeding followed. Intake accounted for only part of the effects of heat stress. Heat stress reduced the milk protein concentration, casein number, and casein concentration and increased the urea concentration in milk beyond the effects of restriction of intake. Under HS, the proportion in total casein of αS1-casein increased and the proportion of αS2-casein decreased. Because no effect of HS on milk fat or lactose concentration was found, these effects appeared to be the result of specific downregulation of mammary protein synthesis, and not a general reduction in mammary activity. No residual effects were found of HS or TN-R on milk production or composition after THI<70 and ad libitum intake were restored. Heat-stressed cows had elevated blood concentrations of urea and Ca, compared with TN-R and TN-AL. Cows in TN-R had higher serum nonesterified fatty acid concentrations than cows in HS. It was proposed that HS and TN-R cows may mobilize different tissues as endogenous sources of energy. Copyright © 2015 American Dairy Science Association. Published by Elsevier Inc. All rights reserved.

  1. Mapping residual stress fields from Vickers hardness indents using Raman microprobe spectroscopy

    DOE Office of Scientific and Technical Information (OSTI.GOV)

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

    Micro-Raman spectroscopy is used to map the residual stress fields in the vicinity of Vickers hardness indents. Both 514.5 and 488.0 nm, light is used to excite the effect and the resulting shifted and broadened Raman peaks are analyzed using computer deconvolution. Half-wave plates are used to vary the orientation of the incident later light`s polarization state with respect to crystal orientation. The Raman scattered light is then analyzed for polarization dependences which are indicative of the various components of the Raman scattering tensor. Such studies can yield valuable information about the orientation of stress components in a well knownmore » stress field. The results can then be applied to the determination of stress components in machined semiconductor materials.« less

  2. Thermal relaxation behavior of residual stress in laser hardened 17-4PH steel after shot peening treatment

    NASA Astrophysics Data System (ADS)

    Wang, Zhou; Chen, Yanhua; Jiang, Chuanhai

    2011-09-01

    In order to investigate the residual stress relaxations of shot peened layer, isothermal annealing treatments were carried out on tempered and laser hardened 17-4PH steel after shot peening with different temperatures from 300 °C to 600 °C. The results showed that the residual stresses were relaxed in the whole deformation layer especially under higher temperature. The maximum rates of stress relaxation took place at the initial stage of annealing process in all conditions. The relaxation process during isothermal annealing could be described by Zener-Wert-Avrami function. The thermal stability of residual stress in tempered 17-4PH was higher than that in laser hardened 17-4PH as well as that in α-iron, which was due to the pinning effects of ɛ-Cu precipitates on the dislocation movement. As massive ɛ-Cu precipitates formed in the temperature about 480 °C, the activation enthalpies for stress relaxation in laser hardened 17-4PH were the same as that in tempered 17-4PH in the conditions of isothermal annealing temperatures of 500 °C and 600 °C.

  3. Relaxation of bending stresses and the reversibility of residual stresses in amorphous soft magnetic alloys

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kekalo, I. B.; Mogil’nikov, P. S., E-mail: pavel-mog@mail.ru

    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 ismore » 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.« less

  4. Optimizing amorphous indium zinc oxide film growth for low residual stress and high electrical conductivity

    NASA Astrophysics Data System (ADS)

    Kumar, Mukesh; Sigdel, A. K.; Gennett, T.; Berry, J. J.; Perkins, J. D.; Ginley, D. S.; Packard, C. E.

    2013-10-01

    With recent advances in flexible electronics, there is a growing need for transparent conductors with optimum conductivity tailored to the application and nearly zero residual stress to ensure mechanical reliability. Within amorphous transparent conducting oxide (TCO) systems, a variety of sputter growth parameters have been shown to separately impact film stress and optoelectronic properties due to the complex nature of the deposition process. We apply a statistical design of experiments (DOE) approach to identify growth parameter-material property relationships in amorphous indium zinc oxide (a-IZO) thin films and observed large, compressive residual stresses in films grown under conditions typically used for the deposition of highly conductive samples. Power, growth pressure, oxygen partial pressure, and RF power ratio (RF/(RF + DC)) were varied according to a full-factorial test matrix and each film was characterized. The resulting regression model and analysis of variance (ANOVA) revealed significant contributions to the residual stress from individual growth parameters as well as interactions of different growth parameters, but no conditions were found within the initial growth space that simultaneously produced low residual stress and high electrical conductivity. Extrapolation of the model results to lower oxygen partial pressures, combined with prior knowledge of conductivity-growth parameter relationships in the IZO system, allowed the selection of two promising growth conditions that were both empirically verified to achieve nearly zero residual stress and electrical conductivities >1480 S/cm. This work shows that a-IZO can be simultaneously optimized for high conductivity and low residual stress.

  5. Residual stress analysis for oxide thin film deposition on flexible substrate using finite element method

    NASA Astrophysics Data System (ADS)

    Chen, Hsi-Chao; Huang, Chen-Yu; Lin, Ssu-Fan; Chen, Sheng-Hui

    2011-09-01

    Residual or internal stresses directly affect a variety of phenomena including adhesion, generation of crystalline defects, perfection of epitaxial layers and formation of film surface growths such as hillocks and whiskers. Sputtering oxide films with high density promote high compressive stress, and it offers researchers a reference if the value of residual stress could be analyzed directly. Since, the study of residual stress of SiO2 and Nb2O5 thin film deposited by DC magnetron sputtered on hard substrate (BK7) and flexible substrate (PET and PC). A finite element method (FEM) with an equivalent-reference-temperature (ERT) technique had been proposed and used to model and evaluate the intrinsic strains of layered structures. The research has improved the equivalent reference temperature (ERT) technique of the simulation of intrinsic strain for oxygen film. The results have also generalized two models connecting to the lattice volume to predict the residual stress of hard substrate and flexible substrate with error of 3% and 6%, respectively.

  6. On the thermally-induced residual stresses in thick fiber-thermoplastic matrix (PEEK) cross-ply laminated plates

    NASA Technical Reports Server (NTRS)

    Hu, Shoufeng; Nairn, John A.

    1992-01-01

    An analytical method for calculating thermally-induced residual stresses in laminated plates is applied to cross-ply PEEK laminates. We considered three cooling procedures: slow cooling (uniform temperature distribution); convective and radiative cooling; and rapid cooling by quenching (constant surface temperature). Some of the calculated stresses are of sufficient magnitude to effect failure properties such as matrix microcracking.

  7. Research on Formation Mechanism of Dynamic Response and Residual Stress of Sheet Metal Induced by Laser Shock Wave

    NASA Astrophysics Data System (ADS)

    Feng, Aixin; Cao, Yupeng; Wang, Heng; Zhang, Zhengang

    2018-01-01

    In order to reveal the quantitative control of the residual stress on the surface of metal materials, the relevant theoretical and experimental studies were carried out to investigate the dynamic response of metal thin plates and the formation mechanism of residual stress induced by laser shock wave. In this paper, the latest research trends on the surface residual stress of laser shock processing technology were elaborated. The main progress of laser shock wave propagation mechanism and dynamic response, laser shock, and surface residual stress were discussed. It is pointed out that the multi-scale characterization of laser and material, surface residual stress and microstructure change is a new hotspot in laser shock strengthening technology.

  8. Modeling the Residual Stresses in Reactive Resins-Based Materials: a Case Study of Photo-Sensitive Composites for Dental Applications

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Grassia, Luigi; D'Amore, Alberto

    Residual stresses in reactive resins-based composites are associated to the net volumetric contraction (shrinkage) arising during the cross-linking reactions. Depending on the restoration geometry (the ratio of the free surface area to the volume of the cavity) the frozen-in stresses can be as high as the strength of the dental composites. This is the main reason why the effectiveness and then the durability of restorations with composites remains quite lower than those realized with metal alloys based materials. In this paper we first explore the possibility to circumvent the mathematical complexity arising from the determination of residual stresses in reactivemore » systems three-dimensionally constrained. Then, the results of our modeling approach are applied to a series of commercially available composites showing that almost all samples develop residual stresses such that the restoration undergoes failure as soon as it is realized.« less

  9. Microbial response to salinity stress in a tropical sandy soil amended with native shrub residues or inorganic fertilizer.

    PubMed

    Sall, Saïdou Nourou; Ndour, Ndèye Yacine Badiane; Diédhiou-Sall, Siré; Dick, Richard; Chotte, Jean-Luc

    2015-09-15

    Soil degradation and salinization caused by inappropriate cultivation practices and high levels of saltwater intrusion are having an adverse effect on agriculture in Central Senegal. The residues of Piliostigma reticulatum, a local shrub that coexists with crops, were recently shown to increase particulate organic matter and improve soil quality and may be a promising means of alleviating the effects of salinization. This study compared the effects of inorganic fertilizer and P. reticulatum residues on microbial properties and the ability of soil to withstand salinity stress. We hypothesized that soils amended with P. reticulatum would be less affected by salinity stress than soils amended with inorganic fertilizer and control soil. Salinity stress was applied to soil from a field site that had been cultivated for 5 years under a millet/peanut crop rotation when microbial biomass, phospholipid fatty acid (PLFA) community profile, catabolic diversity, microbial activities were determined. Microbial biomass, nitrification potential and dehydrogenase activity were higher by 20%, 56% and 69% respectively in soil with the organic amendment. With salinity stress, the structure and activities of the microbial community were significantly affected. Although the biomass of actinobacteria community increased with salinity stress, there was a substantial reduction in microbial activity in all soils. The soil organically amended was, however, less affected by salinity stress than the control or inorganic fertilizer treatment. This suggests that amendment using P. reticulatum residues may improve the ability of soils to respond to saline conditions. Copyright © 2015 Elsevier Ltd. All rights reserved.

  10. Numerical analysis of residual stresses reconstruction for axisymmetric glass components

    NASA Astrophysics Data System (ADS)

    Tao, Bo; Xu, Shuang; Yao, Honghui

    2018-01-01

    A non-destructive measurement method for 3D stress state in a glass cylinder using photoelasticity has been analyzed by simulation in this research. Based on simulated stresses in a glass cylinder, intensity of the cylinder in a circular polariscope can be calculated by Jones calculus. Therefore, the isoclinic angle and optical retardation can be obtained by six steps phase shifting technique. Through the isoclinic angle and optical retardation, the magnitude and distribution of residual stresses inside the glass cylinder in cylindrical coordinate system can be reconstructed. Comparing the reconstructed stresses with numerical simulated stresses, the results verify this non-destructive method can be used to reconstruct the 3D stresses. However, there are some mismatches in axial stress, radial stress and circumferential stress.

  11. Characterization of Flame Cut Heavy Steel: Modeling of Temperature History and Residual Stress Formation

    NASA Astrophysics Data System (ADS)

    Jokiaho, T.; Laitinen, A.; Santa-aho, S.; Isakov, M.; Peura, P.; Saarinen, T.; Lehtovaara, A.; Vippola, M.

    2017-12-01

    Heavy steel plates are used in demanding applications that require both high strength and hardness. An important step in the production of such components is cutting the plates with a cost-effective thermal cutting method such as flame cutting. Flame cutting is performed with a controlled flame and oxygen jet, which burns the steel and forms a cutting edge. However, the thermal cutting of heavy steel plates causes several problems. A heat-affected zone (HAZ) is generated at the cut edge due to the steep temperature gradient. Consequently, volume changes, hardness variations, and microstructural changes occur in the HAZ. In addition, residual stresses are formed at the cut edge during the process. In the worst case, unsuitable flame cutting practices generate cracks at the cut edge. The flame cutting of thick steel plate was modeled using the commercial finite element software ABAQUS. The results of modeling were verified by X-ray diffraction-based residual stress measurements and microstructural analysis. The model provides several outcomes, such as obtaining more information related to the formation of residual stresses and the temperature history during the flame cutting process. In addition, an extensive series of flame cut samples was designed with the assistance of the model.

  12. Residual stress in obliquely deposited MgF2 thin films.

    PubMed

    Jaing, Cheng-Chung; Liu, Ming-Chung; Lee, Cheng-Chung; Cho, Wen-Hao; Shen, Wei-Ting; Tang, Chien-Jen; Liao, Bo-Huei

    2008-05-01

    MgF(2) films with a columnar microstructure are obliquely deposited on glass substrates by resistive heating evaporation. The columnar angles of the films increases with the deposition angle. Anisotropic stress does not develop in the films with tilted columns. The residual stresses in the films depend on the deposition and columnar angles in a columnar microstructure.

  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. Indentation fracture assessment of residual stress in Si{sub 3}N{sub 4}

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Wu, K.H.; Liu, K.C.; Sentella, M.

    1996-12-31

    The measurement of residual stress in Si{sub 3}N{sub 4} ceramics was examined using the indentation technique while a bar specimen with a square cross-section was loaded in tension, and an indentation was created by means of a Vicker`s indenter. The stress applied to the specimen ranged from 0 to 98.8 MPa. The crack length and the shape of the crack were measured by both optical and scanning electron microscopes. Results of the tests indicate that the indentation fracture method can be used to accurately determine the residual stress existing in the material as well as to predict the K{sub c}more » value of the material. The indentation load must be higher than a critical value in order to develop a well-defined penny-shaped crack. For the Si{sub 3}N{sub 4} this critical load is approximately 3 kg. A geometric constant is an important factor for the calculation of the residual stress.« less

  15. Induction of engineered residual stresses fields and enhancement of fatigue life of high reliability metallic components by laser shock processing

    NASA Astrophysics Data System (ADS)

    Ocaña, J. L.; Porro, J. A.; Díaz, M.; Ruiz de Lara, L.; Correa, C.; Gil-Santos, A.; Peral, D.

    2013-02-01

    Laser shock processing (LSP) is being increasingly applied as an effective technology for the improvement of metallic materials mechanical and surface properties in different types of components as a means of enhancement of their corrosion and fatigue life behavior. As reported in previous contributions by the authors, a main effect resulting from the application of the LSP technique consists on the generation of relatively deep compression residual stresses field into metallic alloy pieces allowing an improved mechanical behaviour, explicitly the life improvement of the treated specimens against wear, crack growth and stress corrosion cracking. Additional results accomplished by the authors in the line of practical development of the LSP technique at an experimental level (aiming its integral assessment from an interrelated theoretical and experimental point of view) are presented in this paper. Concretely, follow-on experimental results on the residual stress profiles and associated surface properties modification successfully reached in typical materials (especially Al and Ti alloys characteristic of high reliability components in the aerospace, nuclear and biomedical sectors) under different LSP irradiation conditions are presented along with a practical correlated analysis on the protective character of the residual stress profiles obtained under different irradiation strategies. Additional remarks on the improved character of the LSP technique over the traditional "shot peening" technique in what concerns depth of induced compressive residual stresses fields are also made through the paper.

  16. The numerical high cycle fatigue damage model of fillet weld joint under weld-induced residual stresses

    NASA Astrophysics Data System (ADS)

    Nguyen Van Do, Vuong

    2018-04-01

    In this study, a development of nonlinear continuum damage mechanics (CDM) model for multiaxial high cycle fatigue is proposed in which the cyclic plasticity constitutive model has been incorporated in the finite element (FE) framework. T-joint FE simulation of fillet welding is implemented to characterize sequentially coupled three-dimensional (3-D) of thermo-mechanical FE formulation and simulate the welding residual stresses. The high cycle fatigue damage model is then taken account into the fillet weld joints under the various cyclic fatigue load types to calculate the fatigue life considering the residual stresses. The fatigue crack initiation and the propagation in the present model estimated for the total fatigue is compared with the experimental results. The FE results illustrated that the proposed high cycle fatigue damage model in this study could become a powerful tool to effectively predict the fatigue life of the welds. Parametric studies in this work are also demonstrated that the welding residual stresses cannot be ignored in the computation of the fatigue life of welded structures.

  17. Simulation of balloon angioplasty in residually stressed blood vessels-Application of a gradient-enhanced fibre damage model.

    PubMed

    Polindara, César; Waffenschmidt, Tobias; Menzel, Andreas

    2016-08-16

    In this contribution we study the balloon angioplasty in a residually stressed artery by means of a non-local gradient-enhanced fibre damage model. The balloon angioplasty is a common surgical intervention used to extend or reopen narrowed blood vessels in order to restore the continuous blood flow in, for instance, atherosclerotic arteries. Inelastic, i.e. predominantly damage-related and elastoplastic processes are induced in the artery during its inflation resulting in an irreversible deformation. As a beneficial consequence, provided that the inelastic deformations do not exceed a specific limit, higher deformations can be obtained within the same pressure level and a continuous blood flow can be guaranteed. In order to study the mechanical response of the artery in this scenario, we make use of the non-local gradient-enhanced model proposed in Waffenschmidt et al. (2014). In this contribution, we extend this model to make use of an incompressible format in connection with a Q1Q1P0 finite element implementation. The residual stresses in the artery are also taken into account following the framework presented in Waffenschmidt (2015). From the results it becomes apparent that, when the artery is subjected to radial stresses beyond the physiological range, damage evolution is triggered in the collagen fibres. The impact of the residual stresses on the structural response and on the circumferential stress distribution along the thickness of the arterial wall is also studied. It is observed that the residual stresses have a beneficial effect on the mechanical response of the arterial wall. Copyright © 2016 Elsevier Ltd. All rights reserved.

  18. Retention of Compressive Residual Stresses Introduced by Shot Peening in a Powder Metal Disk Superalloy

    NASA Technical Reports Server (NTRS)

    Gabb, Timothy P.; Danetti, Andrew; Draper, Susan L.; Locci, Ivan E.; Telesman, Jack

    2016-01-01

    The fatigue lives of disk superalloys can be increased by shot peening their surfaces, to induce compressive residual stresses near the surface that impede cracking there. As disk application temperatures increase for improved efficiency, the persistence of these beneficial stresses could be impaired, especially with continued fatigue cycling. The objective of this work was to study the retention of residual stresses introduced by shot peening, when subjected to fatigue and high temperatures. Fatigue specimens of powder metallurgy processed nickel-base disk superalloy ME3 were prepared with consistent processing and heat treatment. They were then shot peened using varied conditions. Strain-controlled fatigue cycles were run at room temperature and 704 C, to allow re-assessment of residual stresses.

  19. Weld Residual Stress and Distortion Analysis of the ARES I-X Upper Stage Simulator (USS)

    NASA Technical Reports Server (NTRS)

    Raju, Ivatury; Dawicke, David; Cheston, Derrick; Phillips, Dawn

    2008-01-01

    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). 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. While the main focus of this paper is a discussion of the weld modeling procedures and results for the USS, a short summary of the CIFS assessment is provided.

  20. 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.

  1. Assessment of Residual Stresses in 3013 Inner and Outer Containers and Teardrop Samples

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Stroud, Mary Ann; Prime, Michael Bruce; Veirs, Douglas Kirk

    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.

  2. 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.

  3. Residual Stresses in Ta, Mo, Al and Pd Thin Films Deposited by E-Beam Evaporation Process on Si and Si/SiO2 Substrates

    NASA Astrophysics Data System (ADS)

    Guisbiers, G.; Strehle, S.; Van Overschelde, O.; Wautelet, M.

    2006-02-01

    Residual stresses are commonly generated during the deposition process of thin films and can influence the reliability of the deposited systems e.g. due to fatigue, aging effects or debonding. Therefore, an evaluation of such stresses in thin films is of crucial importance for metallization of microelectronic devices and MEMS. Residual stresses can be determined experimentally by substrate curvature or X-ray diffraction measurements. The modeling of residual stresses generally deals with the calculation of the thermal ones alone. In the present work, a model is proposed, where intrinsic stresses are calculated explicitly based on the Tsui-Clyne model. The aim of this model, called self-consistent model, is to predict residual stresses in thin films independent on measurements. The simulated values are compared with experimental results for the following systems: Ta/Si, Mo/Si, Al/SiO2/Si and Pd/SiO2/Si.

  4. Residual stress in thick low-pressure chemical-vapor deposited polycrystalline SiC coatings on Si substrates

    NASA Astrophysics Data System (ADS)

    Choi, D.; Shinavski, R. J.; Steffier, W. S.; Spearing, S. M.

    2005-04-01

    Residual stress in thick coatings of polycrystalline chemical-vapor deposited SiC on Si substrates is a key variable that must be controlled if SiC is to be used in microelectromechanical systems. Studies have been conducted to characterize the residual stress level as a function of deposition temperature, Si wafer and SiC coating thickness, and the ratios of methyltrichlorosilane to hydrogen and hydrogen chloride. Wafer curvature was used to monitor residual stress in combination with a laminated plate analysis. Compressive intrinsic (growth) stresses were measured with magnitudes in the range of 200-300MPa; however, these can be balanced with the tensile stress due to the thermal-expansion mismatch to leave near-zero stress at room temperature. The magnitude of the compressive intrinsic stress is consistent with previously reported values of surface stress in combination with the competition between grain-boundary energy and elastic strain energy.

  5. On residual stresses and homeostasis: an elastic theory of functional adaptation in living matter.

    PubMed

    Ciarletta, P; Destrade, M; Gower, A L

    2016-04-26

    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.

  6. Creep-induced residual stress strengthening in a Nicalon-fiber-reinforced BMAS-glass-ceramic-matrix composite

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Widjaja, S.; Jakus, K.; Ritter, J.E.

    The feasibility of inducing a compressive residual stress in the matrix of a Nicalon-fiber-reinforced BMAS-glass-ceramic-matrix composite through a creep-load transfer treatment was studied. Specimens were crept at 1100 C under constant tensile load to cause load transfer from the matrix to the fibers, then cooled under load. Upon removal of the load at room temperature, the matrix was put into compression by the elastic recovery of the fibers. This compressive residual stress in the matrix increased the room-temperature proportional limit stress of the composite. The increase in the proportional limit stress was found to be dependent upon the applied creepmore » stress, with an increase in creep stress resulting in an increase in the proportional limit stress. Acoustic emission results showed that the onset of significant matrix cracking correlated closely to the proportional limit stress. Changes in the state of residual stress in the matrix were supported by X-ray diffraction results. Fracture surfaces of all specimens exhibited fiber pullout behavior, indicating that the creep-load transfer process did not embrittle the fiber/matrix interface.« less

  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. Improved structural integrity through advances in reliable residual stress measurement: the impact of ENGIN-X

    NASA Astrophysics Data System (ADS)

    Edwards, L.; Santisteban, J. R.

    The determination of accurate reliable residual stresses is critical to many fields of structural integrity. Neutron stress measurement is a non-destructive technique that uniquely provides insights into stress fields deep within engineering components and structures. As such, it has become an increasingly important tool within engineering, leading to improved manufacturing processes to reduce stress and distortion as well as to the definition of more precise lifing procedures. This paper describes the likely impact of the next generation of dedicated engineering stress diffractometers currently being constructed and the utility of the technique using examples of residual stresses both beneficial and detrimental to structural integrity.

  9. The Combined Effects of Stress Concentration and Tensile Stresses from Autofrettage on the Life of Pressure Vessels

    DTIC Science & Technology

    2017-02-01

    Technical Report ARWSB-TR-17011 THE COMBINED EFFECTS OF STRESS CONCENTRATION AND TENSILE STRESSES FROM AUTOFRETTAGE ON THE LIFE OF...SUBTITLE THE COMBINED EFFECTS OF STRESS CONCENTRATION AND TENSILE STRESSES FROM AUTOFRETTAGE ON THE LIFE OF PRESSURE VESSELS 5a. CONTRACT NUMBER...hydraulically or mechanically overstrained in order to impart favorable near bore residual compressive hoop stresses in an attempt to enhance fatigue life. As a

  10. THE COMBINED EFFECTS OF STRESS CONCENTRATION AND TENSILE STRESSES FROM AUTOFRETTAGE ON THE LIFE OF PRESSURE VESSELS

    DTIC Science & Technology

    2017-02-22

    Technical Report ARWSB-TR-17011 THE COMBINED EFFECTS OF STRESS CONCENTRATION AND TENSILE STRESSES FROM AUTOFRETTAGE ON THE LIFE OF...SUBTITLE THE COMBINED EFFECTS OF STRESS CONCENTRATION AND TENSILE STRESSES FROM AUTOFRETTAGE ON THE LIFE OF PRESSURE VESSELS 5a. CONTRACT NUMBER...hydraulically or mechanically overstrained in order to impart favorable near bore residual compressive hoop stresses in an attempt to enhance fatigue life. As a

  11. Influence of thermal residual stress on behaviour of metal matrix composites reinforced with particles

    NASA Astrophysics Data System (ADS)

    Guzmán, R. E.; Hernández Arroyo, E.

    2016-02-01

    The properties of a metallic matrix composites materials (MMC's) reinforced with particles can be affected by different events occurring within the material in a manufacturing process. The existence of residual stresses resulting from the manufacturing process of these materials (MMC's) can markedly differentiate the curves obtained in tensile tests obtained from compression tests. One of the themes developed in this work is the influence of residual stresses on the mechanical behaviour of these materials. The objective of this research work presented is numerically estimate the thermal residual stresses using a unit cell model for the Mg ZC71 alloy reinforced with SiC particles with volume fraction of 12% (hot-forging technology). The MMC's microstructure is represented as a three dimensional prismatic cube-shaped with a cylindrical reinforcing particle located in the centre of the prism. These cell models are widely used in predicting stress/strain behaviour of MMC's materials, in this analysis the uniaxial stress/strain response of the composite can be obtained through the calculation using the commercial finite-element code.

  12. Eddy current spectroscopy for near-surface residual stress profiling in surface treated nonmagnetic engine alloys

    NASA Astrophysics Data System (ADS)

    Abu-Nabah, Bassam A.

    Recent research results indicated that eddy current conductivity measurements can be exploited for nondestructive evaluation of near-surface residual stresses in surface-treated nickel-base superalloy components. Most of the previous experimental studies were conducted on highly peened (Almen 10-16A) specimens that exhibit harmful cold work in excess of 30% plastic strain. Such high level of cold work causes thermo-mechanical relaxation at relatively modest operational temperatures; therefore the obtained results were not directly relevant to engine manufacturers and end users. The main reason for choosing peening intensities in excess of recommended normal levels was that in low-conductivity engine alloys the eddy current penetration depth could not be forced below 0.2 mm without expanding the measurements above 10 MHz which is beyond the operational range of most commercial eddy current instruments. As for shot-peened components, it was initially felt that the residual stress effect was more difficult to separate from cold work, texture, and inhomogeneity effects in titanium alloys than in nickel-base superalloys. In addition, titanium alloys have almost 50% lower electric conductivity than nickel-base superalloys; therefore require proportionally higher inspection frequencies, which was not feasible until our recent breakthrough in instrument development. Our work has been focused on six main aspects of this continuing research, namely, (i) the development of an iterative inversion technique to better retrieve the depth-dependent conductivity profile from the measured frequency-dependent apparent eddy current conductivity (AECC), (ii) the extension of the frequency range up to 80 MHz to better capture the peak compressive residual stress in nickel-base superalloys using a new eddy current conductivity measuring system, which offers better reproducibility, accuracy and measurement speed than the previously used conventional systems, (iii) the lift-off effect on

  13. Thermal oxidation of medical Ti6Al4V blasted with ceramic particles: Effects on the microstructure, residual stresses and mechanical properties.

    PubMed

    Lieblich, M; Barriuso, S; Multigner, M; González-Doncel, G; González-Carrasco, J L

    2016-02-01

    Roughening of Ti6Al4V by blasting with alumina or zirconia particles improves the mechanical fixation of implants by increasing the surface area available for bone/implant apposition. Additional thermal oxidation treatments of the blasted alloy have already shown to be a complementary low-cost solution to enhancing the in vitro biocompatibility and corrosion resistance of the alloy. In this work, the effects of oxidation treatment on a grit blasted Ti6Al4V biomedical alloy have been analysed in order to understand the net effect of the combined treatments on the alloy fatigue properties. Synchrotron radiation diffraction experiments have been performed to measure residual stresses before and after the treatments and microstructural and hardness changes have been determined. Although blasting of Ti6Al4V with small spherical zirconia particles increases the alloy fatigue resistance with respect to unblasted specimens, fatigue strength after oxidation decreases below the unblasted value, irrespective of the type of particle used for blasting. Moreover, at 700°C the as-blasted compressive residual stresses (700MPa) are not only fully relaxed but even moderate tensile residual stresses, of about 120MPa, are found beneath the blasted surfaces. Contrary to expectations, a moderate increase in hardness occurs towards the blasted surface after oxidation treatments. This can be attributed to the fact that grit blasting modifies the crystallographic texture of the Ti6Al4V shifting it to a random texture, which affects the hardness values as shown by additional experiments on cold rolled samples. The results indicate that the oxidation treatment performed to improve biocompatibility and corrosion resistance of grit blasted Ti6Al4V should be carried out with caution since the alloy fatigue strength can be critically diminished below the value required for high load-bearing components. Copyright © 2015 Elsevier Ltd. All rights reserved.

  14. Finite-Element Analysis of Residual Stresses Generated Under Nitriding Process: a Three-Dimensional Model

    NASA Astrophysics Data System (ADS)

    Sawicki, J.; Siedlaczek, P.; Staszczyk, A.

    2018-03-01

    A numerical three-dimensional model for computing residual stresses generated in cross section of steel 42CrMo4 after nitriding is presented. The diffusion process is analyzed by the finite-element method. The internal stresses are computed using the obtained profile of the distribution of the nitrogen concentration. The special features of the intricate geometry of the treated articles including edges and angles are considered. Comparative analysis of the results of the simulation and of the experimental measurement of residual stresses is performed by the Waisman-Philips method.

  15. Stress Measurements in Railroad Wheels Via the Barkhausen Effect

    DOT National Transportation Integrated Search

    1977-02-01

    The feasibility of utilizing the Barkhausen Effect in ferromagnetic steels as a nondestructive means for ascertaining residual stresses in railroad wheels was investigated. Railroad wheels are generally manufactured with compressive stress distributi...

  16. Influence of engineered interfaces on residual stresses and mechanical response in metal matrix composites

    NASA Technical Reports Server (NTRS)

    Arnold, Steven M.; Wilt, Thomas E.

    1992-01-01

    Because of the inherent coefficient of thermal expansion (CTE) mismatch between fiber and matrix within metal and intermetallic matrix composite systems, high residual stresses can develop under various thermal loading conditions. These conditions include cooling from processing temperature to room temperature as well as subsequent thermal cycling. As a result of these stresses, within certain composite systems, radial, circumferential, and/or longitudinal cracks have been observed to form at the fiber matrix interface region. A number of potential solutions for reducing this thermally induced residual stress field have been proposed recently. Examples of some potential solutions are high CTE fibers, fiber preheating, thermal anneal treatments, and an engineered interface. Here the focus is on designing an interface (by using a compensating/compliant layer concept) to reduce or eliminate the thermal residual stress field and, therefore, the initiation and propagation of cracks developed during thermal loading. Furthermore, the impact of the engineered interface on the composite's mechanical response when subjected to isothermal mechanical load histories is examined.

  17. Residual transpiration as a component of salinity stress tolerance mechanism: a case study for barley.

    PubMed

    Hasanuzzaman, Md; Davies, Noel W; Shabala, Lana; Zhou, Meixue; Brodribb, Tim J; Shabala, Sergey

    2017-06-19

    While most water loss from leaf surfaces occurs via stomata, part of this loss also occurs through the leaf cuticle, even when the stomata are fully closed. This component, termed residual transpiration, dominates during the night and also becomes critical under stress conditions such as drought or salinity. Reducing residual transpiration might therefore be a potentially useful mechanism for improving plant performance when water availability is reduced (e.g. under saline or drought stress conditions). One way of reducing residual transpiration may be via increased accumulation of waxes on the surface of leaf. Residual transpiration and wax constituents may vary with leaf age and position as well as between genotypes. This study used barley genotypes contrasting in salinity stress tolerance to evaluate the contribution of residual transpiration to the overall salt tolerance, and also investigated what role cuticular waxes play in this process. Leaves of three different positions (old, intermediate and young) were used. Our results show that residual transpiration was higher in old leaves than the young flag leaves, correlated negatively with the osmolality, and was positively associated with the osmotic and leaf water potentials. Salt tolerant varieties transpired more water than the sensitive variety under normal growth conditions. Cuticular waxes on barley leaves were dominated by primary alcohols (84.7-86.9%) and also included aldehydes (8.90-10.1%), n-alkanes (1.31-1.77%), benzoate esters (0.44-0.52%), phytol related compounds (0.22-0.53%), fatty acid methyl esters (0.14-0.33%), β-diketones (0.07-0.23%) and alkylresorcinols (1.65-3.58%). A significant negative correlation was found between residual transpiration and total wax content, and residual transpiration correlated significantly with the amount of primary alcohols. Both leaf osmolality and the amount of total cuticular wax are involved in controlling cuticular water loss from barley leaves under well

  18. 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

  19. Residual Stress Analysis in Girth-welded Ferritic and Austenitic Steel Pipes Using Neutron and X-Ray Diffraction

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Hempel, Nico; Bunn, Jeffrey R; Nitschke-Pagel, Thomas

    This paper is dedicated to the thorough experimental analysis of the residual stresses in the vicinity of tubular welds and the mechanisms involved in their formation. Pipes made of a ferritic-pearlitic structural steel and an austenitic stainless steel are investigated in this study. The pipes feature a similar geometry and are MAG welded with two passes and comparable parameters. Residual strain mappings are carried out using X-ray and neutron diffraction. The combined use of both techniques permits both near-surface and through-wall analyses of the residual stresses. The findings allow for a consistent interpretation of the mechanisms accounting for the formationmore » of the residual stress fields due to the welding process. Since the results are similar for both materials, it can be concluded that residual stresses induced by phase transformations, which can occur in the structural steel, play a minor role in this regard.« less

  20. Remarks on residual stress measurement by hole-drilling and electronic speckle pattern interferometry.

    PubMed

    Barile, Claudia; Casavola, Caterina; Pappalettera, Giovanni; Pappalettere, Carmine

    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.

  1. 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

  2. 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.

  3. Surface mechanical property and residual stress of peened nickel-aluminum bronze determined by in-situ X-ray diffraction

    NASA Astrophysics Data System (ADS)

    Wang, Chengxi; Jiang, Chuanhai; Zhao, Yuantao; Chen, Ming; Ji, Vincent

    2017-10-01

    As one of the most important surface strengthening method, shot peening is widely used to improve the fatigue and stress corrosion crack resistance of components by introducing the refined microstructure and compressive residual stress in the surface layer. However, the mechanical properties of this thin layer are different from the base metal and are difficult to be characterized by conventional techniques. In this work, a micro uniaxial tensile tester equipped with in-situ X-ray stress analyzer was employed to make it achievable on a nickel-aluminum bronze with shot peening treatment. According to the equivalent stress-strain relationship based on Von Mises stress criterion, the Young's modulus and yield strength of the peened layer were calculated. The results showed that the Young's modulus was the same as the bulk material, and the yield strength corresponding to the permanent plastic strain of 0.2% was increased by 21% after SP. But the fractographic analysis showed that the fracture feature of the surface layer was likely to transform from the dimple to the cleavage, indicating the improved strength might be attained at the expense of ductility. The monotonic and cyclic loading were also performed via the same combined set-up. In addition, the specific relaxation behavior of compressive residual stress was quantified by linear logarithm relationship between residual stress and cycle numbers. It was found that the compressive residual stress mainly relaxed in the first few cycles, and then reached steady state with further cycles. The relaxation rate and the stable value were chiefly depended on the stress amplitude and number of cycles. The retained residual stress kept in compressive under all given applied stress levels, suggesting that the shot peening could introduce a more stable surface layer of compressive residual stress other than the elevated strength of nickel-aluminum bronze alloy.

  4. Modelling the layer-specific three-dimensional residual stresses in arteries, with an application to the human aorta

    PubMed Central

    Holzapfel, Gerhard A.; Ogden, Ray W.

    2010-01-01

    This paper provides the first analysis of the three-dimensional state of residual stress and stretch in an artery wall consisting of three layers (intima, media and adventitia), modelled as a circular cylindrical tube. The analysis is based on experimental results on human aortas with non-atherosclerotic intimal thickening documented in a recent paper by Holzapfel et al. ( Holzapfel et al. 2007 Ann. Biomed. Eng. 35, 530–545 (doi:10.1007/s10439-006-9252-z)). The intima is included in the analysis because it has significant thickness and load-bearing capacity, unlike in a young, healthy human aorta. The mathematical model takes account of bending and stretching in both the circumferential and axial directions in each layer of the wall. Previous analysis of residual stress was essentially based on a simple application of the opening-angle method, which cannot accommodate the three-dimensional residual stretch and stress states observed in experiments. The geometry and nonlinear kinematics of the intima, media and adventitia are derived and the associated stress components determined explicitly using the nonlinear theory of elasticity. The theoretical results are then combined with the mean numerical values of the geometrical parameters and material constants from the experiments to illustrate the three-dimensional distributions of the stretches and stresses throughout the wall. The results highlight the compressive nature of the circumferential stress in the intima, which may be associated with buckling of the intima and its delamination from the media, and show that the qualitative features of the stretch and stress distributions in the media and adventitia are unaffected by the presence or absence of the intima. The circumferential residual stress in the intima increases significantly as the associated residual deformation in the intima increases while the corresponding stress in the media (which is compressive at its inner boundary and tensile at its outer

  5. 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.

  6. Defence response of tomato seedlings to oxidative stress induced by phenolic compounds from dry olive mill residue.

    PubMed

    García-Sánchez, Mercedes; Garrido, Inmaculada; Casimiro, Ilda de Jesús; Casero, Pedro Joaquín; Espinosa, Francisco; García-Romera, Inmaculada; Aranda, Elisabet

    2012-10-01

    ADOR is an aqueous extract obtained from the dry olive mill residue (DOR) which contains the majority of its soluble phenolic compounds, which are responsible for its phytotoxic properties. Some studies have shown that ADOR negatively affects seed germination. However, to date, few studies have been carried out on the effect of ADOR on the oxidative stress of the plant. It is well known that saprobe fungi can detoxify these phenolic compounds and reduce the potential negative effects of ADOR on plants. To gain a better understanding of the phytotoxic effects and oxidative stress caused by this residue, tomato seeds were germinated in the presence of ADOR, treated and untreated with Coriolopsis rigida, Trametes versicolor, Pycnoporus cinnabarinus and Penicillium chrysogenum-10 saprobe fungi. ADOR sharply reduced tomato seed germination and also generated high levels of malondialdehyde (MDA), O(2)(-) and H(2)O(2). However, bioremediated ADOR did not negatively affect germination and reduced MDA, O(2)(-) and H(2)O(2) content in different ways depending on the fungus used. In addition, the induced defense response was studied by analyzing the activity of both antioxidant enzymes (superoxide dismutase (SOD), catalase, ascorbate peroxidasa, glutathione reductase (GR), peroxidases and coniferil alcohol peroxidasa) and detoxification enzymes (glutathione-S-transferase (GST)). Our findings suggest that, because ADOR is capable of inducing oxidative stress, tomato seedlings trigger a defense response through SOD, GR, and GST activity and through antioxidant and lignification processes. On the other hand, the bioremediation of ADOR plays an important role in counteracting the oxidative stress induced by the untreated residue. Copyright © 2012 Elsevier Ltd. All rights reserved.

  7. Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

    NASA Astrophysics Data System (ADS)

    Ji, Shude; Yang, Zhanpeng; Wen, Quan; Yue, Yumei; Zhang, Liguo

    2018-04-01

    Trailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

  8. The Surface Layer Mechanical Condition and Residual Stress Forming Model in Surface Plastic Deformation Process with the Hardened Body Effect Consideration

    NASA Astrophysics Data System (ADS)

    Mahalov, M. S.; Blumenstein, V. Yu

    2017-10-01

    The mechanical condition and residual stresses (RS) research and computational algorithms creation in complex types of loading on the product lifecycle stages relevance is shown. The mechanical state and RS forming finite element model at surface plastic deformation strengthening machining, including technological inheritance effect, is presented. A model feature is the production previous stages obtained transformation properties consideration, as well as these properties evolution during metal particles displacement through the deformation space in the present loading step.

  9. Evolution of Residual Stress and Distortion of Cold-Rolled Bearing Ring from Annealing to Quenched-Tempered Heat Treatment

    NASA Astrophysics Data System (ADS)

    Lu, Bohan; Lu, Xiaohui

    2018-02-01

    This study investigates the correlation between the residual stress and distortion behavior of a cold-rolled ring from the annealing to quenching-tempering (QT) process. Due to the cold-rolled process, the external periphery of the bearing ring experiences a compressive residual stress. To relieve the residual stress, cold-rolled rings are annealed at 700 °C which is higher than the starting temperature of recrystallization. When cold-rolled rings are annealed at 700 °C for 15 min, the compressive residual stress is reduced to zero and the outer diameter of the annealed ring becomes larger than that of a non-annealed sample, which is unrelated to annealing time. Simultaneously, the roundness and taper deviation do not obviously change compared with those of non-annealed sample. The stress relaxation during the annealing process was attributed to the recovery and recrystallization of ferrite. Annealing has a genetic influence on the following QT heat treatment, wherein the lowest residual stress is in the non-annealed cold-rolled ring. From the annealing to QT process, the deviation of the outer diameter, roundness, and taper increased with annealing time, a large extend than that of non-annealed samples.

  10. Residual stress determination in an overlay dissimilar welded pipe by neutron diffraction

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Woo, Wan Chuck; Em, Vyacheslav; Hubbard, Camden R

    2011-01-01

    Residual stresses were determined through the thickness of a dissimilar weld overlay pipe using neutron diffraction. The specimen has a complex joining structure consisting of a ferritic steel (SA508), austenitic steel (F316L), Ni-based consumable (Alloy 182), and overlay of Ni-base superalloy (Alloy 52M). It simulates pressurized nozzle components, which have been a critical issue under the severe crack condition of nuclear power reactors. Two neutron diffractometers with different spatial resolutions have been utilized on the identical specimen for comparison. The macroscopic 'stress-free' lattice spacing (d{sub o}) was also obtained from both using a 2-mm width comb-like coupon. The results showmore » significant changes in residual stresses from tension (300-400 MPa) to compression (-600 MPa) through the thickness of the dissimilar weld overlay pipe specimen.« less

  11. Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

    NASA Technical Reports Server (NTRS)

    Malone, Tina W.; Graham, Benny F.; Gentz, Steven J. (Technical Monitor)

    2001-01-01

    Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

  12. Effect of Activated Flux on the Microstructure, Mechanical Properties, and Residual Stresses of Modified 9Cr-1Mo Steel Weld Joints

    NASA Astrophysics Data System (ADS)

    Maduraimuthu, V.; Vasudevan, M.; Muthupandi, V.; Bhaduri, A. K.; Jayakumar, T.

    2012-02-01

    A novel variant of tungsten inert gas (TIG) welding called activated-TIG (A-TIG) welding, which uses a thin layer of activated flux coating applied on the joint area prior to welding, is known to enhance the depth of penetration during autogenous TIG welding and overcomes the limitation associated with TIG welding of modified 9Cr-1Mo steels. Therefore, it is necessary to develop a specific activated flux for enhancing the depth of penetration during autogeneous TIG welding of modified 9Cr-1Mo steel. In the current work, activated flux composition is optimized to achieve 6 mm depth of penetration in single-pass TIG welding at minimum heat input possible. Then square butt weld joints are made for 6-mm-thick and 10-mm-thick plates using the optimized flux. The effect of flux on the microstructure, mechanical properties, and residual stresses of the A-TIG weld joint is studied by comparing it with that of the weld joints made by conventional multipass TIG welding process using matching filler wire. Welded microstructure in the A-TIG weld joint is coarser because of the higher peak temperature in A-TIG welding process compared with that of multipass TIG weld joint made by a conventional TIG welding process. Transverse strength properties of the modified 9Cr-1Mo steel weld produced by A-TIG welding exceeded the minimum specified strength values of the base materials. The average toughness values of A-TIG weld joints are lower compared with that of the base metal and multipass weld joints due to the presence of δ-ferrite and inclusions in the weld metal caused by the flux. Compressive residual stresses are observed in the fusion zone of A-TIG weld joint, whereas tensile residual stresses are observed in the multipass TIG weld joint.

  13. On the Variation of Hardness Due to Uniaxial and Equi-Biaxial Residual Surface Stresses at Elastic-Plastic Indentation

    NASA Astrophysics Data System (ADS)

    Larsson, Per-Lennart

    2018-05-01

    It is established long since that the material hardness is independent of residual stresses at predominantly plastic deformation close to the contact region at indentation. Recently though, it has been shown that when elastic and plastic deformations are of equal magnitude this invariance is lost. For materials such as ceramics and polymers, this will complicate residual stress determination but can also, if properly understood, provide additional important information for performing such a task. Indeed, when the residual stresses are equi-biaxial, the situation is quite well understood, but additional efforts have to be made to understand the mechanical behavior in other loading states. Presently therefore, the variation of hardness, due to residual stresses, is examined at a uniaxial stress state. Correlation with global indentation quantities is analyzed, discussed and compared to corresponding equi-biaxial results. Cone indentation of elastic-perfectly plastic materials is considered.

  14. Effect of heat treatment on residual stress and wear behaviors of the TiNi/Ti2Ni based laser cladding composite coatings

    NASA Astrophysics Data System (ADS)

    Tao, Yang-Feng; Li, Jun; Lv, Ying-Hao; Hu, Lie-Feng

    2017-12-01

    The TiNi/Ti2Ni based composite coatings reinforced by TiC and TiB2 were prepared on Ti6Al4V at different circumstance temperatures (25 °C, 400 °C, 600 °C, and 800 °C) by laser cladding, then were preserved for 3 h. Macromorphologies and microstructures of the coatings were examined through an optical microscope (OM), an X-ray diffractometer (XRD), a scanning electron microscope (SEM), and an energy dispersive spectrometer (EDS). Residual stresses along the depth direction of the coatings were measured by the nanoindentation method, and wear behaviors of the coatings were also investigated using an ultra-functional wear testing machine. Results showed that the coatings were mainly composed of TiNi/Ti2Ni as the matrix and TiC/TiB2 as the reinforcement. A small amount of Cr2Ti was formed in the coatings prepared at 400 °C and 600 °C. Besides that, Ti3Al was also observed in the coating prepared at 800 °C. The tensile stress existed in the coatings prepared at 25 °C, 400 °C and 600 °C when the coating prepared at 800 °C was regarded as the stress-free reference. The average residual stress in the surface of coating prepared at 25 °C reached the largest value of about 2.79 GPa and presented a decreasing tendency with increasing the circumstance temperature (1.03 GPa at 400 °C, 0.52 GPa at 600 °C, and 0 GPa at 800 °C). It revealed that the rise in circumstance temperature contributed to the reduction in cracking susceptibility in the laser cladding coating. However, the wear volumes of the coatings were increased with increasing the circumstance temperature (0.1912 mm3 at 25 °C, 0.2828 mm3 at 400 °C, 0.3732 mm3 at 600 °C, and 0.6073 mm3 at 800 °C) due to the weakening in strain-hardening effect and the reduction in reinforcement density. The wear mechanism of the coatings was transformed from the single brittle-debonding into the combination of micro-cutting and brittle-debonding when the circumstance temperature was changed from room temperature to

  15. Residual Stress Induced Mechanical Property Enhancement in Steel Encapsulated Light Metal Matrix Composites

    NASA Astrophysics Data System (ADS)

    Fudger, Sean James

    Macro hybridized systems consisting of steel encapsulated light metal matrix composites (MMCs) were produced with the goal of creating a low cost/light weight composite system with enhanced mechanical properties. MMCs are frequently incorporated into advanced material systems due to their tailorable material properties. However, they often have insufficient ductility for many structural applications. The macro hybridized systems take advantage of the high strength, modulus, and damage tolerance of steels and high specific stiffness and low density of MMCs while mitigating the high density of steels and the poor ductility of MMCs. Furthermore, a coefficient of thermal expansion (CTE) mismatch induced residual compressive stress method is utilized as a means of improving the ductility of the MMCs and overall efficiency of the macro hybridized systems. Systems consisting of an A36, 304 stainless steel, or NitronicRTM 50 stainless steel shell filled with an Al-SiC, Al-Al2O3, or Mg-B4C MMC are evaluated in this work. Upon cooling from processing temperatures, residual strains are generated due to a CTE mismatch between each of the phases. The resulting systems offer higher specific properties and a more structurally efficient system can be attained. Mechanical testing was performed and improvements in yield stress, ultimate tensile stress, and ductility were observed. However, the combination of these dissimilar materials often results in the formation of intermetallic compounds. In certain loading situations, these typically brittle intermetallic layers can result in degraded performance. X-ray Diffraction (XRD), X-ray Energy Dispersive Spectroscopy (EDS), and Electron Backscatter Diffraction (EBSD) are utilized to characterize the intermetallic layer formation at the interface between the steel and MMC. As the residual stress condition in each phase has a large impact on the mechanical property improvement, accurate quantification of these strains/stresses is

  16. Triaxial X-Ray Diffraction Method and its Application to Monitor Residual Stress in Surface Layers after High-Feed Milling

    NASA Astrophysics Data System (ADS)

    Zaušková, Lucia; Czán, Andrej; Šajgalík, Michal; Pobijak, Jozef; Mikloš, Matej

    2017-10-01

    High-feed milling is a milling method characteristic with shallow depth of cut and high feed rate to maximize the amount of removed metal from a part, generating residual stresses in the surface and subsurface layers of the machined parts. The residual stress has a large influence on the functional properties of the components. The article is focused on the application of triaxial x-ray diffraction method to monitor residual stresses after high feed milling. Significance of triaxial measuring method is the capability of measuring in different angles so it is possible to acquire stress tensor containing normal and shear stress components.

  17. Influence of cooling rate on residual stress profile in veneering ceramic: measurement by hole-drilling.

    PubMed

    Mainjot, Amélie K; Schajer, Gary S; Vanheusden, Alain J; Sadoun, Michaël J

    2011-09-01

    The manufacture of dental crowns and bridges generates residual stresses within the veneering ceramic and framework during the cooling process. Residual stress is an important factor that control the mechanical behavior of restorations. Knowing the stress distribution within the veneering ceramic as a function of depth can help the understanding of failures, particularly chipping, a well-known problem with Yttria-tetragonal-zirconia-polycrystal based fixed partial dentures. The objective of this study is to investigate the cooling rate dependence of the stress profile in veneering ceramic layered on metal and zirconia frameworks. The hole-drilling method, often used for engineering measurements, was adapted for use with veneering ceramic. The stress profile was measured in bilayered disc samples 20 mm in diameter, with a 0.7 mm thick metal or Yttria-tetragonal-zirconia-polycrystal framework and a 1.5mm thick veneering ceramic. Three different cooling procedures were investigated. The magnitude of the stresses in the surface of the veneering ceramic was found to increase with cooling rate, while the interior stresses decreased. At the surface, compressive stresses were observed in all samples. In the interior, compressive stresses were observed in metal samples and tensile in zirconia samples. Cooling rate influences the magnitude of residual stresses. These can significantly influence the mechanical behavior of metal-and zirconia-based bilayered systems. The framework material influenced the nature of the interior stresses, with zirconia samples showing a less favorable stress profile than metal. Copyright © 2011 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  18. Relief of Residual Stress in Streamline Tie Rods by Heat Treatment

    NASA Technical Reports Server (NTRS)

    Pollard, R E; Reinhart, Fred M

    1941-01-01

    About two-thirds of the residual stress in cold-worked SAE 1050 steel tie rods was relieved by heating 30 minutes at 600 degrees Fahrenheit. Cold-worked austenitic stainless-steel tie rods could be heated at temperatures up to 1000 degrees Fahrenheit without lowering the important physical properties. The corrosion resistance, in laboratory corrosion test, of straight 18:8 and titanium-treated 18:8 materials appeared to be impaired after heating at temperatures above 800 degrees or 900 degrees fahrenheit. Columbium-treated and molybdenum-treated 18:8 steel exhibited improved stability over a wide range of temperatures. Tie rods of either material could be heated 30 minutes with safety at any temperature up to 1000 degrees Fahrenheit. At this temperature most of the residual stress would be relieved.

  19. 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.

  20. Measurement of Young's modulus and residual stress of thin SiC layers for MEMS high temperature applications

    NASA Astrophysics Data System (ADS)

    Pabst, Oliver; Schiffer, Michael; Obermeier, Ernst; Tekin, Tolga; Lang, Klaus Dieter; Ngo, Ha-Duong

    2011-06-01

    Silicon carbide (SiC) is a promising material for applications in harsh environments. Standard silicon (Si) microelectromechanical systems (MEMS) are limited in operating temperature to temperatures below 130 °C for electronic devices and below 600 °C for mechanical devices. Due to its large bandgap SiC enables MEMS with significantly higher operating temperatures. Furthermore, SiC exhibits high chemical stability and thermal conductivity. Young's modulus and residual stress are important mechanical properties for the design of sophisticated SiC-based MEMS devices. In particular, residual stresses are strongly dependent on the deposition conditions. Literature values for Young's modulus range from 100 to 400 GPa, and residual stresses range from 98 to 486 MPa. In this paper we present our work on investigating Young's modulus and residual stress of SiC films deposited on single crystal bulk silicon using bulge testing. This method is based on measurement of pressure-dependent membrane deflection. Polycrystalline as well as single crystal cubic silicon carbide samples are studied. For the samples tested, average Young's modulus and residual stress measured are 417 GPa and 89 MPa for polycrystalline samples. For single crystal samples, the according values are 388 GPa and 217 MPa. These results compare well with literature values.

  1. Thermo-mechanical characterization of a thermoplastic composite and prediction of the residual stresses and lamina curvature during cooling

    NASA Astrophysics Data System (ADS)

    Péron, Mael; Jacquemin, Frédéric; Casari, Pascal; Orange, Gilles; Bailleul, Jean-Luc; Boyard, Nicolas

    2017-10-01

    The prediction of process induced stresses during the cooling of thermoplastic composites still represents a challenge for the scientific community. However, a precise determination of these stresses is necessary in order to optimize the process conditions and thus lower the stresses effects on the final part health. A model is presented here, that permits the estimation of residual stresses during cooling. It relies on the nonlinear laminate theory, which has been adapted to arbitrary layup sequences. The developed model takes into account the heat transfers through the thickness of the laminate, together with the crystallization kinetics. The development of the composite mechanical properties during cooling is addressed by an incremental linear elastic constitutive law, which also considers thermal and crystallization strains. In order to feed the aforementioned model, a glass fiber and PA6.6 matrix unidirectional (UD) composite has been characterized. This work finally focuses on the identification of the material and process related parameters that lower the residual stresses level, including the ply sequence, the fiber volume fraction and the cooling rate.

  2. Boundary element methods for the analysis of crack growth in the presence of residual stress fields

    NASA Astrophysics Data System (ADS)

    Leitao, V. M. A.; Aliabadi, M. H.; Rooke, D. P.; Cook, R.

    1998-06-01

    Two boundary element methods of simulating crack growth in the presence of residual stress fields are presented, and the results are compared to experimental measurements. The first method utilizes linear elastic fracture mechanics (LEFM) and superimposes the solutions due to the applied load and the residual stress field. In this method, the residual stress fields are obtained from an elastoplastic BEM analysis, and numerical weight functions are used to obtain the stress intensity factors due to the fatigue loading. The second method presented is an elastoplastic fracture mechanics (EPFM) approach for crack growth simulation. A nonlinear J-integral is used in the fatigue life calculations. The methods are shown to agree well with experimental measurements of crack growth in prestressed open hole specimens. Results are also presented for the case where the prestress is applied to specimens that have been precracked.

  3. Load transfer mechanics between trans-tibial prosthetic socket and residual limb--dynamic effects.

    PubMed

    Jia, Xiaohong; Zhang, Ming; Lee, Winson C C

    2004-09-01

    The effects of inertial loads on the interface stresses between trans-tibial residual limb and prosthetic socket were investigated. The motion of the limb and prosthesis was monitored using a Vicon motion analysis system and the ground reaction force was measured by a force platform. Equivalent loads at the knee joint during walking were calculated in two cases with and without consideration of the material inertia. A 3D nonlinear finite element (FE) model based on the actual geometry of residual limb, internal bones and socket liner was developed to study the mechanical interaction between socket and residual limb during walking. To simulate the friction/slip boundary conditions between the skin and liner, automated surface-to-surface contact was used. The prediction results indicated that interface pressure and shear stress had the similar double-peaked waveform shape in stance phase. The average difference in interface stresses between the two cases with and without consideration of inertial forces was 8.4% in stance phase and 20.1% in swing phase. The maximum difference during stance phase is up to 19%. This suggests that it is preferable to consider the material inertia effect in a fully dynamic FE model.

  4. 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.

  5. 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.

  6. Estimation of residual stresses in railroad commuter car wheels following manufacture

    DOT National Transportation Integrated Search

    2003-06-01

    A finite element simulation is presented for the prediction of : residual stresses resulting from the heat treatment of railroad : commuter car wheels during manufacture. The quenching and : annealing segments of the wheel manufacturing process are s...

  7. Estimation of residual stresses in railroad commuter car wheels following manufacture

    DOT National Transportation Integrated Search

    1998-11-01

    A finite element simulation is presented for the prediction of residual stresses resulting from the heat treatment of railroad commuter car wheels during manufacture. The quenching and annealing segments of the wheel manufacturing process are simulat...

  8. Growth and Comparison of Residual Stress of AlN Films on Silicon (100), (110) and (111) Substrates

    NASA Astrophysics Data System (ADS)

    Pandey, Akhilesh; Dutta, Shankar; Prakash, Ravi; Raman, R.; Kapoor, Ashok Kumar; Kaur, Davinder

    2018-02-01

    This paper reports on the comparison of residual stresses in AlN thin films sputter-deposited in identical conditions on Si (100) (110) and (111) substrates. The deposited films are of polycrystalline wurtzite structure with preferred orientation along the (002) direction. AlN film on the Si (111) substrate showed a vertical columnar structure, whereas films on Si (100) and (110) showed tilted columnar structures. Residual stress in the AlN films is estimated by x-ray diffraction (XRD), infra-red absorption method and wafer curvature technique. Films residual stress are found compressive and values are in the range of - 650 (± 50) MPa, - 730 (± 50) MPa and - 300 (± 50) MPa for the AlN films grown on Si (100), (110) and (111) substrates, respectively, with different techniques. The difference in residual stresses can be attributed to the microstructure of the films and mismatch between in plane atomic arrangements of the film and substrates.

  9. Real-time patient-specific finite element analysis of internal stresses in the soft tissues of a residual limb: a new tool for prosthetic fitting.

    PubMed

    Portnoy, S; Yarnitzky, G; Yizhar, Z; Kristal, A; Oppenheim, U; Siev-Ner, I; Gefen, A

    2007-01-01

    Fitting of a prosthetic socket is a critical stage in the process of rehabilitation of a trans-tibial amputation (TTA) patient, since a misfit may cause pressure ulcers or a deep tissue injury (DTI: necrosis of the muscle flap under intact skin) in the residual limb. To date, prosthetic fitting typically depends on the subjective skills of the prosthetist, and is not supported by biomedical instrumentation that allows evaluation of the quality of fitting. Specifically, no technology is presently available to provide real-time continuous information on the internal distribution of mechanical stresses in the residual limb during fitting of the prosthesis, or while using it and this severely limits patient evaluations. In this study, a simplified yet clinically oriented patient-specific finite element (FE) model of the residual limb was developed for real-time stress analysis. For this purpose we employed a custom-made FE code that continuously calculates internal stresses in the residual limb, based on boundary conditions acquired in real-time from force sensors, located at the limb-prosthesis interface. Validation of the modeling system was accomplished by means of a synthetic phantom of the residual limb, which allowed simultaneous measurements of interface pressures and internal stresses. Human studies were conducted subsequently in five TTA patients. The dimensions of bones and soft tissues were obtained from X-rays of the residual limb of each patient. An indentation test was performed in order to obtain the effective elastic modulus of the soft tissues of the residual limb. Seven force sensors were placed between the residual limb and the prosthetic liner, and subjects walked on a treadmill during analysis. Generally, stresses under the shinbones were approximately threefold higher than stresses at the soft tissues behind the bones. Usage of a thigh corset decreased the stresses in the residual limb during gait by approximately 80%. Also, the stresses

  10. Simulation of residual stresses and their effects on thermal barrier coating systems using finite element method

    NASA Astrophysics Data System (ADS)

    Zhu, JianGuo; Chen, Wei; Xie, HuiMin

    2015-03-01

    Thermal barrier coating (TBC) systems are widely used in industrial gas-turbine engines. However, premature failures have impaired the use of TBCs and cut down their lifetime, which requires a better understanding of their failure mechanisms. In the present study, experimental studies of isothermal cycling are firstly carried out with the observation and estimation of microstructures. According to the experimental results, a finite element model is established for the analysis of stress perpendicular to the TBC/BC interface. Detailed residual stress distributions in TBC are obtained to reflect the influence of mechanical properties, oxidation, and interfacial roughness. The calculated results show that the maximum tensile stress concentration appears at the peak of TBC and continues to increase with thermal cycles. Because of the microstructural characteristics of plasma-sprayed TBCs, cracks initialize in tensile stress concentration (TSC) regions at the peaks of TBC and propagate along the TBC/BC interface resulting in the spallation of TBC. Also, the inclusion of creep is crucial to failure prediction and is more important than the inclusion of sintering in the simulation.

  11. A kinetic approach to evaluate salinity effects on carbon mineralization in a plant residue-amended soil*

    PubMed Central

    Nourbakhsh, Farshid; Sheikh-Hosseini, Ahmad R.

    2006-01-01

    The interaction of salinity stress and plant residue quality on C mineralization kinetics in soil is not well understood. A laboratory experiment was conducted to study the effects of salinity stress on C mineralization kinetics in a soil amended with alfalfa, wheat and corn residues. A factorial combination of two salinity levels (0.97 and 18.2 dS/m) and four levels of plant residues (control, alfalfa, wheat and corn) with three replications was performed. A first order kinetic model was used to describe the C mineralization and to calculate the potentially mineralizable C. The CO2-C evolved under non-saline condition, ranged from 814.6 to 4842.4 mg CO2-C/kg in control and alfalfa residue-amended soils, respectively. Salinization reduced the rates of CO2 evolution by 18.7%, 6.2% and 5.2% in alfalfa, wheat and corn residue-amended soils, respectively. Potentially mineralizable C (C 0) was reduced significantly in salinized alfalfa residue-treated soils whereas, no significant difference was observed for control treatments as well as wheat and corn residue-treated soils. We concluded that the response pattern of C mineralization to salinity stress depended on the plant residue quality and duration of incubation. PMID:16972320

  12. 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

  13. Influence of veneer thickness on residual stress profile in veneering ceramic: measurement by hole-drilling.

    PubMed

    Mainjot, Amélie K; Schajer, Gary S; Vanheusden, Alain J; Sadoun, Michaël J

    2012-02-01

    The veneering process of frameworks induces residual stresses and can initiate cracks when combined with functional stresses. The stress distribution within the veneering ceramic as a function of depth is a key factor influencing failure by chipping. This is a well-known problem with Yttria-tetragonal-zirconia-polycrystal based fixed partial dentures. The objective of this study is to investigate the influence of veneer thickness on the stress profile in zirconia- and metal-based structures. The hole-drilling method, often used for engineering measurements, was adapted for use with veneering ceramic. The stress profile was measured in bilayered disc samples of 20 mm diameter, with a 1 mm thick zirconia or metal framework. Different veneering ceramic thicknesses were performed: 1 mm, 1.5 mm, 2 mm, 2.5 mm and 3 mm. All samples exhibited the same type of stress vs. depth profile, starting with compressive at the ceramic surface, decreasing with depth up to 0.5-1.0 mm from the surface, and then becoming compressive again near the framework, except for the 1.5 mm-veneered zirconia samples which exhibited interior tensile stresses. Stresses in the surface of metal samples were not influenced by veneer thickness. Variation of interior stresses at 1.2 mm from the surface in function of veneer thickness was inverted for metal and zirconia samples. Veneer thickness influences in an opposite way the residual stress profile in metal- and in zirconia-based structures. A three-step approach and the hypothesis of the crystalline transformation are discussed to explain the less favorable residual stress development in zirconia samples. Copyright © 2011 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  14. Properties and Residual Stresses in Angle-Ply Polymer Matrix Composites

    DTIC Science & Technology

    1982-03-01

    AMMRC TR 82-12 PROPERTIES AND RES l DUAL STRESSES IN ANGLE-PLY POLYMER MATR l X COMPOSITES March 1982 ABDEL A. FAHMY,, HARVEY A. WEST, and MARK...m D.e. Enl.r.d) PROPERTIES AND RESIDUAL STRESSES I N ANGLE-PLY F i n a l Report POLYMER MATRIX COMPOSITES REPORTDOCUMENTATlON PAGE I 7. AUTHOR...SUPPLEMENTARV NOTES L 19. KEY WORDS (Comclrm. m r.r.r. wd. 11 ner..sw and idenllfy by blocb nmb-r) Composites Thermal expansion Epoxy l a m i n a t e s

  15. 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

  16. Effects of Loading Frequency on Fatigue Behavior, Residual Stress, and Microstructure of Deep-Rolled Stainless Steel AISI 304 at Elevated Temperatures

    NASA Astrophysics Data System (ADS)

    Nikitin, I.; Juijerm, P.

    2018-02-01

    The effects of loading frequency on the fatigue behavior of non-deep-rolled (NDR) and deep-rolled (DR) austenitic stainless steel AISI 304 were systematically clarified at elevated temperatures, especially at temperatures exhibiting the dynamic strain aging (DSA) phenomena. Tension-compression fatigue tests were performed isothermally at temperatures of 573 K and 773 K (300 °C and 500 °C) with different loading frequencies of 5, 0.5, 0.05, and 0.005 Hz. For the DR condition, the residual stresses and work-hardening states will be presented. It was found that DSA would be detected at appropriate temperatures and deformation rates. The cyclic deformation curves and the fatigue lives of the investigated austenitic stainless steel AISI 304 are considerably affected by the DSA, especially on the DR condition having high dislocation densities at the surface and in near-surface regions. In the temperature range of the DSA, residual stresses and work-hardening states of the DR condition seem to be stabilized. The microstructural alterations were investigated by transmission electron microscopy (TEM). At an appropriate temperature with low loading frequency, the plastic deformation mechanism shifted from a wavy slip manner to a planar slip manner in the DSA regimes, whereas the dislocation movements were obstructed.

  17. Oxidative Stress Induced in Sunflower Seedling Roots by Aqueous Dry Olive-Mill Residues

    PubMed Central

    Garrido, Inmaculada; García-Sánchez, Mercedes; Casimiro, Ilda; Casero, Pedro Joaquin; García-Romera, Inmaculada; Ocampo, Juan Antonio; Espinosa, Francisco

    2012-01-01

    The contamination of soils with dry olive-mill residue can represent a serious problem as being an environmental stressor in plants. It has been demonstrated that inoculation of aqueous extract of olive oil-mill residue (ADOR) with saprobe fungi removes some phenolic compounds. In this paper we studied the effect of ADOR uninoculated or inoculated with saprobe fungi in sunflower seedling roots. The germination and root growth, O2·- generation, superoxide dismutase (SOD) and extracellular peroxidases (EC-POXs) activities, and the content of some metabolites involved in the tolerance of stress were tested. The roots germinated in ADOR uninoculated show a decrease in meristem size, resulting in a reduction of the root length and fresh weight, and in the number of layers forming the cortex, but did not alter the dry weight, protein and soluble amino acid content. ADOR caused the decreases in O2·- generation and EC-POX′s activities and protein oxidation, but enhanced SOD activity, lipid peroxidation and proline content. Fluorescence imaging showed that ADOR induced O2·- and H2O2 accumulation in the roots. The increase in SOD and the decrease in EC-POX′s activities might be involved in the enhancement of H2O2 content and lipid peroxidation. Control roots treated with ADOR for 10 min show an oxidative burst. Roots germinated in ADOR inoculated with saprobe fungi partially recovered normal levels of ROS, morphological characteristics and antioxidant activities. These results suggested that treatment with ADOR caused a phytotoxic effect during germination inducing an oxidative stress. The inoculation of ADOR with saprobe fungi limited the stress. PMID:23049960

  18. CONDENSED MATTER: ELECTRONIC STRUCTURE, ELECTRICAL, MAGNETIC, AND OPTICAL PROPERTIES: Influence of Ytterbia Content on Residual Stress and Microstructure of Y2O3-ZrO2 Thin Films Prepared by EB-PVD*

    NASA Astrophysics Data System (ADS)

    Xiao, Qi-Ling; Shao, Sriu-Ying; He, Hong-Bo; Shao, Jian-Da; Fan, Zheng-Xiu

    2008-09-01

    Y2O3 stabilized ZrO2 (YSZ) thin films with different Y2O3 molar contents (0, 3, 7, and 12mol%) are deposited on BK7 substrates by electron-beam evaporation technique. The effects of different Y2O3 contents on residual stresses and structures of YSZ thin films are studied. Residual stresses are investigated by means of two different techniques: the curvature measurement and x-ray diffraction method. It is found that the evolution of residual stresses of YSZ thin films by the two different methods is consistent. Residual stresses of films transform from compressive stress into tensile stress and the tensile stress incre ases monotonically with the increase of Y2O3 content. At the same time, the structures of these films change from the mixture of amorphous and monoclinic phases into high temperature cubic phase. The variations of residual stress correspond to the evolution of structures induced by adding of Y2O3 content.

  19. Residual stress relief due to fatigue in tetragonal lead zirconate titanate ceramics

    NASA Astrophysics Data System (ADS)

    Hall, D. A.; Mori, T.; Comyn, T. P.; Ringgaard, E.; Wright, J. P.

    2013-07-01

    High energy synchrotron XRD was employed to determine the lattice strain ɛ{111} and diffraction peak intensity ratio R{200} in tetragonal PZT ceramics, both in the virgin poled state and after a bipolar fatigue experiment. It was shown that the occurrence of microstructural damage during fatigue was accompanied by a reduction in the gradient of the ɛ{111}-cos2 ψ plot, indicating a reduction in the level of residual stress due to poling. In contrast, the fraction of oriented 90° ferroelectric domains, quantified in terms of R{200}, was not affected significantly by fatigue. The change in residual stress due to fatigue is interpreted in terms of a change in the average elastic stiffness of the polycrystalline matrix due to the presence of inter-granular microcracks.

  20. Study of grain-level deformation and residual stresses in Ti-7Al under combined bending and tension using high energy diffraction microscopy (HEDM)

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Chatterjee, K.; Venkataraman, A.; Garbaciak, T.

    In-situ high energy diffraction microscopy (HEDM) experiments are carried out to analyze the state of combined bending and tension in a Ti-7Al alloy under room temperature creep. Grain-level elastic strain tensors are evaluated from HEDM data. Atomistic calculations are used to predict elastic constants of Ti-7Al, to be used in determination of stress from strain. The stress gradient and residual stresses are successfully determined, which allows the demarcation between macro-/micro-level residual stresses. A cluster of three neighboring grains are identified that highlight the variation of mean and effective stress between grains. Crystallographic orientations and slip characteristics are analyzed for themore » selected grains. It is inferred that the interfaces between loaded grains with markedly different stress triaxiality and slip tendency are potential spots for material damage.« less

  1. Implementation of thermal residual stresses in the analysis of fiber bridged matrix crack growth in titanium matrix composites

    NASA Technical Reports Server (NTRS)

    Bakuckas, John G., Jr.; Johnson, W. Steven

    1994-01-01

    In this research, thermal residual stresses were incorporated in an analysis of fiber-bridged matrix cracks in unidirectional and cross-ply titanium matrix composites (TMC) containing center holes or center notches. Two TMC were investigated, namely, SCS-6/Timelal-21S laminates. Experimentally, matrix crack initiation and growth were monitored during tension-tension fatigue tests conducted at room temperature and at an elevated temperature of 200 C. Analytically, thermal residual stresses were included in a fiber bridging (FB) model. The local R-ratio and stress-intensity factor in the matrix due to thermal and mechanical loadings were calculated and used to evaluate the matrix crack growth behavior in the two materials studied. The frictional shear stress term, tau, assumed in this model was used as a curve-fitting parameter to matrix crack growth data. The scatter band in the values of tau used to fit the matrix crack growth data was significantly reduced when thermal residual stresses were included in the fiber bridging analysis. For a given material system, lay-up and temperature, a single value of tau was sufficient to analyze the crack growth data. It was revealed in this study that thermal residual stresses are an important factor overlooked in the original FB models.

  2. Diffraction grating strain gauge method: error analysis and its application for the residual stress measurement in thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Yin, Yuanjie; Fan, Bozhao; He, Wei; Dai, Xianglu; Guo, Baoqiao; Xie, Huimin

    2018-03-01

    Diffraction grating strain gauge (DGSG) is an optical strain measurement method. Based on this method, a six-spot diffraction grating strain gauge (S-DGSG) system has been developed with the advantages of high and adjustable sensitivity, compact structure, and non-contact measurement. In this study, this system is applied for the residual stress measurement in thermal barrier coatings (TBCs) combining the hole-drilling method. During the experiment, the specimen’s location is supposed to be reset accurately before and after the hole-drilling, however, it is found that the rigid body displacements from the resetting process could seriously influence the measurement accuracy. In order to understand and eliminate the effects from the rigid body displacements, such as the three-dimensional (3D) rotations and the out-of-plane displacement of the grating, the measurement error of this system is systematically analyzed, and an optimized method is proposed. Moreover, a numerical experiment and a verified tensile test are conducted, and the results verify the applicability of this optimized method successfully. Finally, combining this optimized method, a residual stress measurement experiment is conducted, and the results show that this method can be applied to measure the residual stress in TBCs.

  3. Transient and residual stresses in large castings, taking time effects into account

    NASA Astrophysics Data System (ADS)

    Thorborg, J.; Klinkhammer, J.; Heitzer, M.

    2012-07-01

    Casting of large scale steel and iron parts leads to long solidification and cooling times. Solid mechanical calculations for these castings have to take the time scale of the process into account, in order to predict the transient and residual stress levels with a reasonable accuracy. This paper presents a study on the modelling of the thermo-mechanical conditions in the cast material using a unified approach to describe the constitutive behaviour. This means a classical splitting of the mechanical strain into an elastic and an inelastic contribution, where the inelastic strain is only formulated in the deviatoric space in terms of the J2 invariant. At high temperatures, creep is pronounced. Since the cooling time is long, the model includes a type of Norton's power law to integrate the significant contribution of creep to the inelastic strains. At these temperature levels, annealing effects are also dominant and hence no hardening is modelled. However, at intermediate and lower temperature levels, hardening is more pronounced and isotropic hardening is considered. Different hardening models have been studied and selected based on their ability to describe the behaviour at the different temperature levels. At the lower temperature levels, time effects decrease and the formulation reduces to a time independent formulation, like classical J2-flow theory. Several tensile and creep experiments have been made at different temperature levels to provide input data for selecting the appropriate contributions to the material model. The measurements have furthermore been used as input for extracting material data for the model. The numerical model is applied on different industrial examples to verify the agreement between measured and calculated deformations.

  4. On the Eigenstrain Application of Shot-peened Residual Stresses within a Crystal Plasticity Framework: Application to Ni-base Superalloy Specimens (Postprint)

    DTIC Science & Technology

    2015-07-08

    Compressive surface residual stresses can be applied via multi ple techniques (shot/gravity peening, low plasticity burnishing, laser shock peening...eigenstrains are used include internal stresses due to inclusions/particles or fibers [48], differences in coefficient of thermal expansion of different phases...residual stresses induced by shot peening [44,52 54], laser shock peening [55 61], and welding [62 66]. For shot peening analysis, the amount of residual

  5. Effect of controlling recrystallization from the melt on the residual stress and structural properties of the Silica-clad Ge core fiber

    NASA Astrophysics Data System (ADS)

    Zhao, Ziwen; Cheng, Xueli; He, Ting; Xue, Fei; Zhang, Wei; Chen, Na; Wen, Jianxiang; Zeng, Xianglong; Wang, Tingyun

    2017-09-01

    Effect of controlling recrystallization from the melt (1000 °C) on the residual stress and structural properties of a Ge core fiber via molten core drawing (MCD) method is investigated. Ge core fibers is investigated using Raman spectroscopy, scanning electron microscope (SEM), and X-ray diffraction (XRD). Compared with the as-drawn Ge fiber, the Raman peak of the recrystallized Ge fiber shift from 300 cm-1 to 300.6 cm-1 and full width at half maximum (FWHM) decreased from 5.36 cm-1 to 4.48 cm-1. The Ge crystal grains which sizes are of 200-600 nm were formed during the process of recrystallization; the XRD peak of (1 1 1) plane is observed after recrystallization. These results show that controlling recrystallization allows the release of the thermal stress, and improvement of the crystal quality of Ge core.

  6. Evolution of Microstructure and Residual Stress under Various Vibration Modes in 304 Stainless Steel Welds

    PubMed Central

    Wang, Peng-Shuen; Wang, Jia-Siang

    2014-01-01

    Simultaneous vibration welding of 304 stainless steel was carried out with an eccentric circulating vibrator and a magnetic telescopic vibrator at subresonant (362 Hz and 59.3 Hz) and resonant (376 Hz and 60.9 Hz) frequencies. The experimental results indicate that the temperature gradient can be increased, accelerating nucleation and causing grain refinement during this process. During simultaneous vibration welding primary δ-ferrite can be refined and the morphologies of retained δ-ferrite become discontinuous so that δ-ferrite contents decrease. The smallest content of δ-ferrite (5.5%) occurred using the eccentric circulating vibrator. The diffraction intensities decreased and the FWHM widened with both vibration and no vibration. A residual stress can obviously be increased, producing an excellent effect on stress relief at a resonant frequency. The stress relief effect with an eccentric circulating vibrator was better than that obtained using a magnetic telescopic vibrator. PMID:24605068

  7. Onsager's symmetry relation and the residual parallel Reynolds stress in a magnetized plasma with electrostatic turbulence

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Zuo, Yang, E-mail: yangzustc@gmail.com; Wang, Shaojie

    2014-09-15

    The physics of the residual parallel Reynolds stress in a rotating plasma with electrostatic turbulence is explicitly identified by using the transport formulation of the gyrokinetic turbulence. It is clarified that the residual stress consists of four terms, among which are the cross terms due to the pressure gradient and the temperature gradient and the terms related to the turbulent acceleration impulse and the turbulent heating rate. The last two terms are identified for the first time, and are shown to cause analogous residual term in the heat flux. Meanwhile, the transport matrix reveals diffusion in the phase space. Themore » transport matrix is demonstrated to satisfy the Onsager's symmetry relation.« less

  8. Thermal residual stresses in silicon-carbide/titanium (0/90) laminate

    NASA Technical Reports Server (NTRS)

    Bigelow, C. A.

    1992-01-01

    The current work formulated a micromechanical analysis of a cross-ply laminate and calculated the thermal residual stress in a very thick (0/90)(sub 2n) silicon-carbide/titanium laminate. Results were also shown for a unidirectional laminate of the same material. Discrete fiber-matrix models assuming a rectangular array of fibers with a fiber volume fraction of 32.5 percent and a three-dimensional, finite-element analysis were used. Significant differences in the trends and magnitudes for the fiber, matrix, and interface stresses were calculated for unidirectional and (0/90) models. Larger hoop stresses calculated for the (0/90) model indicate that it may be more susceptible to radial cracking when subjected to mechanical loading than the unidirectional model. The axial stresses in the matrix were calculated to be slightly larger for the (0/90) model. The compressive axial stresses in the fiber were significantly larger in the (0/90) model. The presence of the cross-ply in the (0/90) model reduced the constraint on the fiber, producing radial interface stresses that were less compressive, which could lead to earlier failure of the fiber-matrix interface.

  9. Determination of welding residual stresses by inverse approach with eigenstrain formulations of boundary integral equation

    NASA Astrophysics Data System (ADS)

    Ma, Hang; Wang, Ying; Qin, Qing-Hua

    2011-04-01

    Based on the concept of eigenstrain, a straightforward computational model of the inverse approach is proposed for determining the residual stress field induced by welding using the eigenstrain formulations of boundary integral equations. The eigenstrains are approximately expressed in terms of low-order polynomials in the local area around welded zones. The domain integrals with polynomial eigenstrains are transformed into the boundary integrals to preserve the favourable features of the boundary-only discretization in the process of numerical solutions. The sensitivity matrices in the inverse approach for evaluating the eigenstrain fields are constructed by either the measured deformations (displacements) on the boundary or the measured stresses in the domain after welding over a number of selected measuring points, or by both the measured information. It shows from the numerical examples that the results of residual stresses from deformation measurements are always better than those from stress measurements but they are sensitive to the noises from experiments. The results from stress measurements can be improved by introducing a few deformation measuring points while reducing the number of points for stress measuring to reduce the cost since the measurement of deformation is easier than that of stresses in practice.

  10. Dynamic response and residual stress fields of Ti6Al4V alloy under shock wave induced by laser shock peening

    NASA Astrophysics Data System (ADS)

    Sun, Rujian; Li, Liuhe; Zhu, Ying; Zhang, Lixin; Guo, Wei; Peng, Peng; Li, Bo; Guo, Chao; Liu, Lei; Che, Zhigang; Li, Weidong; Sun, Jianfei; Qiao, Hongchao

    2017-09-01

    Laser shock peening (LSP), an innovative surface treatment technique, generates compressive residual stress on the surface of metallic components to improve their fatigue performance, wear resistance and corrosion resistance. To illustrate the dynamic response during LSP and residual stress fields after LSP, this study conducted FEM simulations of LSP in a Ti6Al4V alloy. Results showed that when power density was 7 GW cm-2, a plastic deformation occurred at 10 ns during LSP and increased until the shock pressure decayed below the dynamic yield strength of Ti6Al4V after 60 ns. A maximum tensile region appeared beneath the surface at around 240 ns, forming a compressive-tensile-compressive stress sandwich structure with a thickness of 98, 1020 and 606 μm for each layer. After the model became stabilized, the value of the surface residual compressive stress was 564 MPa at the laser spot center. Higher value of residual stress across the surface and thicker compressive residual stress layers were achieved by increasing laser power density, impact times and spot sizes during LSP. A ‘Residual stress hole’ occurred with a high laser power density of 9 GW cm-2 when laser pulse duration was 10 ns, or with a long laser pulse duration of 20 ns when laser power density was 7 GW cm-2 for Ti6Al4V. This phenomenon occurred because of the permanent reverse plastic deformation generated at laser spot center.

  11. Characterization of Mechanical Properties and Residual Stress in API 5L X80 Steel Welded Joints

    NASA Astrophysics Data System (ADS)

    de Sousa Lins, Amilton; de Souza, Luís Felipe Guimarães; Fonseca, Maria Cindra

    2018-01-01

    The use of high-strength and low-alloy steels, high design factors and increasingly stringent safety requirements have increased the operating pressure levels and, consequently, the need for further studies to avoid and prevent premature pipe failure. To evaluate the possibility of improving productivity in manual arc welding of this type of steel, this work characterizes the mechanical properties and residual stresses in API 5L X80 steel welded joints using the SMAW and FCAW processes. The residual stresses were analyzed using x-ray diffraction with the sin2 ψ method at the top and root of the welded joints in the longitudinal and transverse directions of the weld bead. The mechanical properties of the welded joints by both processes were characterized in terms of tensile strength, impact toughness and Vickers microhardness in the welded and shot peening conditions. A predominantly compressive residual stress was found, and shot peening increased the tensile strength and impact toughness in both welded joints.

  12. Study of the location of testing area in residual stress measurement by Moiré interferometry combined with hole-drilling method

    NASA Astrophysics Data System (ADS)

    Qin, Le; Xie, HuiMin; Zhu, RongHua; Wu, Dan; Che, ZhiGang; Zou, ShiKun

    2014-04-01

    This paper investigates the effect of the location of testing area in residual stress measurement by Moiré interferometry combined with hole-drilling method. The selection of the location of the testing area is analyzed from theory and experiment. In the theoretical study, the factors which affect the surface released radial strain ɛ r were analyzed on the basis of the formulae of the hole-drilling method, and the relations between those factors and ɛ r were established. By combining Moiré interferometry with the hole-drilling method, the residual stress of interference-fit specimen was measured to verify the theoretical analysis. According to the analysis results, the testing area for minimizing the error of strain measurement is determined. Moreover, if the orientation of the maximum principal stress is known, the value of strain will be measured with higher precision by the Moiré interferometry method.

  13. Analysis of residual transverse stresses in a thick UD glass/polyester pultruded profile using hole drilling with strain gage and digital image correlation

    NASA Astrophysics Data System (ADS)

    Yuksel, Onur; Baran, Ismet; Ersoy, Nuri; Akkerman, Remko

    2018-05-01

    Process induced stresses inherently exist in fiber reinforced polymer composites particularly in thick parts due to the presence of non-uniform cure, shrinkage and thermal expansion/contraction during manufacturing. In order to increase the reliability and the performance of the composite materials, process models are developed to predict the residual stress formation. The accuracy of the process models is dependent on the geometrical (micro to macro), material and process parameters as well as the numerical implementation. Therefore, in order to have reliable process modelling framework, there is a need for validation and if necessary calibration of the developed models. This study focuses on measurement of the transverse residual stresses in a relatively thick pultruded profile (20×20 mm) made of glass/polyester. Process-induced residual stresses in the middle of the profile are examined with different techniques which have never been applied for transverse residual stresses in thick unidirectional composites. Hole drilling method with strain gage and digital image correlation are employed. Strain values measured from measurements are used in a finite element model (FEM) to simulate the hole drilling process and predict the residual stress level. The measured released strain is found to be approximately 180 μm/m from the strain gage. The tensile residual stress at the core of the profile is estimated approximately as 7-10 MPa. Proposed methods and measured values in this study will enable validation and calibration of the process models based on the residual stresses.

  14. Residual stress profiles in veneering ceramic on Y-TZP, alumina and ZTA frameworks: measurement by hole-drilling.

    PubMed

    Fukushima, K A; Sadoun, M J; Cesar, P F; Mainjot, A K

    2014-02-01

    The residual stress profile developed within the veneering ceramic during the manufacturing process is an important predicting factor in chipping failures, which constitute a well-known problem with yttria-tetragonal-zirconia polycrystal (Y-TZP) based restorations. The objectives of this study are to measure and to compare the residual stress profile in the veneering ceramic layered on three different polycrystalline ceramic framework materials: Y-TZP, alumina polycrystal (AL) and zirconia toughened alumina (ZTA). The stress profile was measured with the hole-drilling method in bilayered disk samples of 19 mm diameter with a 0.7 mm thick Y-TZP, AL or ZTA framework and a 1.5mm thick layer of the corresponding veneering ceramic. The AL samples exhibited increasing compressive stresses with depth, while compressive stresses switching into interior tensile stresses were measured in Y-TZP samples. ZTA samples exhibited compressive stress at the ceramic surface, decreasing with depth up to 0.6mm from the surface, and then becoming compressive again near the framework. Y-TZP samples exhibited a less favorable stress profile than those of AL and ZTA samples. Results support the hypothesis of the occurrence of structural changes within the Y-TZP surface in contact with the veneering ceramic to explain the presence of tensile stresses. Even if the presence of Y-TZP in the alumina matrix seems to negatively affect the residual stress profiles in ZTA samples in comparison with AL samples, the registered profiles remain positive in terms of veneer fracture resistance. Copyright © 2013 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  15. Thermal deformations and stresses in composite materials

    NASA Technical Reports Server (NTRS)

    Daniel, I. M.

    1980-01-01

    Residual stresses are induced during curing in angle-ply laminates as a result of anisotropic thermal deformations of the variously oriented plies. Residual strains are measured experimentally using embedded strain gage techniques, and residual stresses are computed using orthotropic stress-strain relations. The results show that, for graphite and Kevlar laminates, residual stresses at room temperature are high enough to cause damage in the plies in the transverse to the fiber direction. It is also shown that residual stresses do not relax appreciably. The ply stacking sequence is found to have no effect on the magnitude of average residual stresses. Residual stresses and susceptibility to cracking during curing depend to a marked extent on ply layup.

  16. Effect of sputtering pressure on crystalline quality and residual stress of AlN films deposited at 823 K on nitrided sapphire substrates by pulsed DC reactive sputtering

    NASA Astrophysics Data System (ADS)

    Ohtsuka, Makoto; Takeuchi, Hiroto; Fukuyama, Hiroyuki

    2016-05-01

    Aluminum nitride (AlN) is a promising material for use in applications such as deep-ultraviolet light-emitting diodes (UV-LEDs) and surface acoustic wave (SAW) devices. In the present study, the effect of sputtering pressure on the surface morphology, crystalline quality, and residual stress of AlN films deposited at 823 K on nitrided a-plane sapphire substrates, which have high-crystalline-quality c-plane AlN thin layers, by pulsed DC reactive sputtering was investigated. The c-axis-oriented AlN films were homoepitaxially grown on nitrided sapphire substrates at sputtering pressures of 0.4-1.5 Pa. Surface damage of the AlN sputtered films increased with increasing sputtering pressure because of arcing (abnormal electrical discharge) during sputtering. The sputtering pressure affected the crystalline quality and residual stress of AlN sputtered films because of a change in the number and energy of Ar+ ions and Al sputtered atoms. The crystalline quality of AlN films was improved by deposition with lower sputtering pressure.

  17. Residual Stress Development in Explosive-Bonded Bi-Metal Composite Materials

    DTIC Science & Technology

    2014-03-01

    at ANSTO, researching high temperature fatigue behaviour and modelling of ferritic pressure vessel steel , for which he was awarded the degree at...solidification cracking in steels and stainless steels . He has also undertaken extensive work on improving the weld zone toughness of high strength steels ...957. [3] I. Tatsukawa, I. Oda, ‘Residual Stress Measurements on Explosive Clad Stainless Steel ’, Trans. Japan Welding Soc., 2(2), 1971, p26-34

  18. Prediction of microstructure, residual stress, and deformation in laser powder bed fusion process

    NASA Astrophysics Data System (ADS)

    Yang, Y. P.; Jamshidinia, M.; Boulware, P.; Kelly, S. M.

    2018-05-01

    Laser powder bed fusion (L-PBF) process has been investigated significantly to build production parts with a complex shape. Modeling tools, which can be used in a part level, are essential to allow engineers to fine tune the shape design and process parameters for additive manufacturing. This study focuses on developing modeling methods to predict microstructure, hardness, residual stress, and deformation in large L-PBF built parts. A transient sequentially coupled thermal and metallurgical analysis method was developed to predict microstructure and hardness on L-PBF built high-strength, low-alloy steel parts. A moving heat-source model was used in this analysis to accurately predict the temperature history. A kinetics based model which was developed to predict microstructure in the heat-affected zone of a welded joint was extended to predict the microstructure and hardness in an L-PBF build by inputting the predicted temperature history. The tempering effect resulting from the following built layers on the current-layer microstructural phases were modeled, which is the key to predict the final hardness correctly. It was also found that the top layers of a build part have higher hardness because of the lack of the tempering effect. A sequentially coupled thermal and mechanical analysis method was developed to predict residual stress and deformation for an L-PBF build part. It was found that a line-heating model is not suitable for analyzing a large L-PBF built part. The layer heating method is a potential method for analyzing a large L-PBF built part. The experiment was conducted to validate the model predictions.

  19. Prediction of microstructure, residual stress, and deformation in laser powder bed fusion process

    NASA Astrophysics Data System (ADS)

    Yang, Y. P.; Jamshidinia, M.; Boulware, P.; Kelly, S. M.

    2017-12-01

    Laser powder bed fusion (L-PBF) process has been investigated significantly to build production parts with a complex shape. Modeling tools, which can be used in a part level, are essential to allow engineers to fine tune the shape design and process parameters for additive manufacturing. This study focuses on developing modeling methods to predict microstructure, hardness, residual stress, and deformation in large L-PBF built parts. A transient sequentially coupled thermal and metallurgical analysis method was developed to predict microstructure and hardness on L-PBF built high-strength, low-alloy steel parts. A moving heat-source model was used in this analysis to accurately predict the temperature history. A kinetics based model which was developed to predict microstructure in the heat-affected zone of a welded joint was extended to predict the microstructure and hardness in an L-PBF build by inputting the predicted temperature history. The tempering effect resulting from the following built layers on the current-layer microstructural phases were modeled, which is the key to predict the final hardness correctly. It was also found that the top layers of a build part have higher hardness because of the lack of the tempering effect. A sequentially coupled thermal and mechanical analysis method was developed to predict residual stress and deformation for an L-PBF build part. It was found that a line-heating model is not suitable for analyzing a large L-PBF built part. The layer heating method is a potential method for analyzing a large L-PBF built part. The experiment was conducted to validate the model predictions.

  20. Calculation of the shrinkage-induced residual stress in a viscoelastic dental restorative material

    NASA Astrophysics Data System (ADS)

    Grassia, Luigi; D'Amore, Alberto

    2013-02-01

    A procedure able to describe the curing process of a particulate composite material used in a dental restoration is developed in the ANSYS environment. The material under concern is a multifunctional methacrylate-based composite for dental restoration, activated by visible light. The model accounts for the dependence of the viscoelastic functions on temperature and degree of cure. Three geometries have been considered in the analysis that are representative of three different classes of dental restoration and mainly differ by the C (constrained)-factor, (i.e. the bounded to unbounded surface ratio). It was found that the temperature could give a necrosis in the vicinity of the tooth nerve and that the average stress at the interface between the composite and the tooth scales exponentially with the C-factor. The residual stress at the dental restoration interface is also compared with the uniaxial tensile strength of twelve commercially available composite materials: it clearly appears that the level of residual stress may overcome the strength of the composite, especially at high C-factors.

  1. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in ODS Steel MA956

    DTIC Science & Technology

    2013-06-01

    dispersion strengthened - Eurofer steel ,” J. Nucl. Mater., vol. 416 , pp. 2229, Sep 1, 2011. [10] H. J. K. Lemmen and K. J. Sudmeijer, I, “Laser beam...Reynolds and W. Tang, “Structure, properties, and residual stress of 304L stainless steel friction stir welds,” Scr. Mater., vol. 48, pp. 12891294...OF RESIDUAL STRESS AS A FUNCTION OF FRICTION STIR WELDING PARAMETERS IN ODS STEEL MA956 by Martin S. Bennett June 2013 Thesis Advisor

  2. Concurrent tailoring of fabrication process and interphase layer to reduce residual stresses in metal matrix composites

    NASA Technical Reports Server (NTRS)

    Saravanos, D. A.; Chamis, C. C.; Morel, M.

    1991-01-01

    A methodology is presented to reduce the residual matrix stresses in continuous fiber metal matrix composites (MMC) by optimizing the fabrication process and interphase layer characteristics. The response of the fabricated MMC was simulated based on nonlinear micromechanics. Application cases include fabrication tailoring, interphase tailoring, and concurrent fabrication-interphase optimization. Two composite systems, silicon carbide/titanium and graphite/copper, are considered. Results illustrate the merits of each approach, indicate that concurrent fabrication/interphase optimization produces significant reductions in the matrix residual stresses and demonstrate the strong coupling between fabrication and interphase tailoring.

  3. 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

  4. Ultra-high strain in epitaxial silicon carbide nanostructures utilizing residual stress amplification

    NASA Astrophysics Data System (ADS)

    Phan, Hoang-Phuong; Nguyen, Tuan-Khoa; Dinh, Toan; Ina, Ginnosuke; Kermany, Atieh Ranjbar; Qamar, Afzaal; Han, Jisheng; Namazu, Takahiro; Maeda, Ryutaro; Dao, Dzung Viet; Nguyen, Nam-Trung

    2017-04-01

    Strain engineering has attracted great attention, particularly for epitaxial films grown on a different substrate. Residual strains of SiC have been widely employed to form ultra-high frequency and high Q factor resonators. However, to date, the highest residual strain of SiC was reported to be limited to approximately 0.6%. Large strains induced into SiC could lead to several interesting physical phenomena, as well as significant improvement of resonant frequencies. We report an unprecedented nanostrain-amplifier structure with an ultra-high residual strain up to 8% utilizing the natural residual stress between epitaxial 3C-SiC and Si. In addition, the applied strain can be tuned by changing the dimensions of the amplifier structure. The possibility of introducing such a controllable and ultra-high strain will open the door to investigating the physics of SiC in large strain regimes and the development of ultra sensitive mechanical sensors.

  5. Use of the Contour Method to Determine Autofrettage Residual Stresses: A Proposed Experimental Procedure

    DTIC Science & Technology

    2013-05-01

    autofrettage of a long tube: Residual hoop, radial and axial stresses, 70% overstrain, numerical, open-end Autofrettage of A723 steel including non- linear...concentrate axial stresses which are expected to range between 18% of yield in compression at the bore to 15% in tension at the OD. So the zone of the...experiments is that they were conducted on axially thin (quasi plane stress) ring specimens cut from much longer gun tubes. A recent paper [2

  6. 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 (K I) stress intensity factor (SIF) along the cut tip, and correlating trends in K I to CIP development.« less

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

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

    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 (K I) stress intensity factor (SIF) along the cut tip, and correlating trends in K I to CIP development.« less

  8. Residual stresses investigations in composite samples by speckle interferometry and specimen repositioning

    NASA Astrophysics Data System (ADS)

    Baldi, Alfonso; Jacquot, Pierre

    2003-05-01

    Graphite-epoxy laminates are subjected to the "incremental hole-drilling" technique in order to investigate the residual stresses acting within each layer of the composite samples. In-plane speckle interferometry is used to measure the displacement field created by each drilling increment around the hole. Our approach features two particularities (1) we rely on the precise repositioning of the samples in the optical set-up after each new boring step, performed by means of a high precision, numerically controlled milling machine in the workshop; (2) for each increment, we acquire three displacement fields, along the length, the width of the samples, and at 45°, using a single symmetrical double beam illumination and a rotary stage holding the specimens. The experimental protocol is described in detail and the experimental results are presented, including a comparison with strain gages. Speckle interferometry appears as a suitable method to respond to the increasing demand for residual stress determination in composite samples.

  9. 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.

  10. Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

    DOE PAGES

    An, Ke; Yuan, Lang; Dial, Laura; ...

    2017-09-11

    Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling downmore » were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.« less

  11. Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    An, Ke; Yuan, Lang; Dial, Laura

    Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling downmore » were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.« less

  12. The Role of Residual Stress in the Performance of Gears and Bearings

    DTIC Science & Technology

    1986-02-01

    stress distribution near the surface of an Infinite half space - a good approximation If the residual stress has arisen from a homogeneous surface...carburlr.ed caae ia shwon in Figure 11. The surface hard». ;ss is in fact for moderate tempering periods at up to 200°C in thia steel. In addition...Concentration 1 10-10 Nc-ln«l Applied Alternating Str«aa/Wa -200 0 200 400 Applied Mean Streaa /M»a rijur» 6 Goodaan DU*raa (KM

  13. Characterization of Residual Stress in Microelectromechanical Systems (MEMS) Devices Using Raman Spectroscopy

    DTIC Science & Technology

    2002-04-01

    residual and induced stress curves . A key to modelling MEMS structures, especially micromirrors , is to 2-23 (a) 0V (b) 10V (c) 20V (d) 40V (e) 50V (f...outlined in Figure 4.20. A line marker is used to extract the FEM data as displayed across the micromirror flexure. The MEMCAD FEM stress curve for the... curved as observed by the number of fringe lines displayed on the micromirror surface. The maximum peak deformation for this series of micromirrors is

  14. Numerical Prediction of Residual Stresses in an Autofrettaged Tube of Compressible Material

    DTIC Science & Technology

    1981-05-01

    2 LEVEL TECHNICAL REPORT ARLCB-TR- 81019 NUMERICAL PREDICTION OF RESIDUAL STRESSES IN AN AUTOFRETTAGED TUBE OF COMPRESSIBLE MATERIAL 7 P. C. T. Chen...DOCUMENTATION PAGE READ INSTRUCTIONS BEFORE COMPLETING FORM I. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT’S CATALOG NUMBER ARLCB-TR- 81019 At

  15. 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

  16. Numerical Investigation of the Residual Stress Distribution of Flat-Faced and Convexly Curved Tablets Using the Finite Element Method.

    PubMed

    Otoguro, Saori; Hayashi, Yoshihiro; Miura, Takahiro; Uehara, Naoto; Utsumi, Shunichi; Onuki, Yoshinori; Obata, Yasuko; Takayama, Kozo

    2015-01-01

    The stress distribution of tablets after compression was simulated using a finite element method, where the powder was defined by the Drucker-Prager cap model. The effect of tablet shape, identified by the surface curvature, on the residual stress distribution was investigated. In flat-faced tablets, weak positive shear stress remained from the top and bottom die walls toward the center of the tablet. In the case of the convexly curved tablet, strong positive shear stress remained on the upper side and in the intermediate part between the die wall and the center of the tablet. In the case of x-axial stress, negative values were observed for all tablets, suggesting that the x-axial force always acts from the die wall toward the center of the tablet. In the flat tablet, negative x-axial stress remained from the upper edge to the center bottom. The x-axial stress distribution differed between the flat and convexly curved tablets. Weak stress remained in the y-axial direction of the flat tablet, whereas an upward force remained at the center of the convexly curved tablet. By employing multiple linear regression analysis, the mechanical properties of the tablets were predicted accurately as functions of their residual stress distribution. However, the multiple linear regression prediction of the dissolution parameters of acetaminophen, used here as a model drug, was limited, suggesting that the dissolution of active ingredients is not a simple process; further investigation is needed to enable accurate predictions of dissolution parameters.

  17. Method to control residual stress in a film structure and a system thereof

    DOEpatents

    Parthum, Sr., Michael J.

    2008-12-30

    A method for controlling residual stress in a structure in a MEMS device and a structure thereof includes selecting a total thickness and an overall equivalent stress for the structure. A thickness for each of at least one set of alternating first and second layers is determined to control an internal stress with respect to a neutral axis for each of the at least alternating first and second layers and to form the structure based on the selected total thickness and the selected overall equivalent stress. Each of the at least alternating first and second layers is deposited to the determined thickness for each of the at least alternating first and second layers to form the structure.

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

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    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 Technologymore » 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.« less

  19. Experimental residual stress evaluation of hydraulic expansion transitions in Alloy 690 steam generator tubing

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    McGregor, R.; Doherty, P.; Hornbach, D.

    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 tubemore » 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.« less

  20. Variability of residual stresses and superposition effect in multipass grinding of high-carbon high-chromium steel

    NASA Astrophysics Data System (ADS)

    Karabelchtchikova, Olga; Rivero, Iris V.

    2005-02-01

    The distribution of residual stresses (RS) and surface integrity generated in heat treatment and subsequent multipass grinding was investigated in this experimental study to examine the source of variability and the nature of the interactions of the experimental factors. A nested experimental design was implemented to (a) compare the sources of the RS variability, (b) to examine RS distribution and tensile peak location due to experimental factors, and (c) to analyze the superposition relationship in the RS distribution due to multipass grinding technique. To characterize the material responses, several techniques were used, including microstructural analysis, hardness-toughness and roughness examinations, and retained austenite and RS measurements using x-ray diffraction. The causality of the RS was explained through the strong correlation of the surface integrity characteristics and RS patterns. The main sources of variation were the depth of the RS distribution and the multipass grinding technique. The grinding effect on the RS was statistically significant; however, it was mostly predetermined by the preexisting RS induced in heat treatment. Regardless of the preceding treatments, the effect of the multipass grinding technique exhibited similar RS patterns, which suggests the existence of the superposition relationship and orthogonal memory between the passes of the grinding operation.

  1. Raman Study of Uncoated and P-bn/sic-coated Hi-nicalon Reinforced Celsian Matrix Composites. Part 2; Residual Stress in the Fibers

    NASA Technical Reports Server (NTRS)

    Gouadec, Gwenael; Colomban, Philippe; Bansal, Narottam P.

    2000-01-01

    Band shifts on Raman spectra were used to assess, at a microscopic scale, the residual strain existing in Hi-Nicalon fibers reinforcing celsian matrix composites. Uncoated as well as p-BN/SiC- and p-B(Si)N/SiC-coated Hi-Nicalon fibers were used as the reinforcements. We unambiguously conclude that the fibers are in a state of compressive residual stress. Quantitative determination of the residual stress was made possible by taking into account the heating induced by laser probing and by using a reference line, of fixed wavenumber. We found fiber compressive residual stress values between 110 and 960 MPa depending on the fiber/matrix coating in the composite. A stress relaxation-like phenomenon was observed at the surface of p-BN/SiC-coated Hi-Nicalon fibers whereas the uncoated or p-B(Si)N/SiC-coated Hi-Nicalon fibers did not show any stress relaxation in the Celsian matrix composites.

  2. Influence and Modeling of Residual Stresses in Thick Walled Pressure Vessels with Through Holes

    DTIC Science & Technology

    2012-02-28

    9 FIGURE 4 ENVIRONMENTAL CRACKING OBSERVED IN EVACUATOR HOLE .......... 9 FIGURE 5 STRESSES PRESENT IN STRAIGHT EVACUATOR... ASSESMENT OF INITIAL DAMAGE Through investigation was undertaken on vessels similar in size and strength level to pressure vessels 85A and 85B...suggesting that the source of the residual stresses required to initiate and propagate these environmental cracks is not a resultant of the typical

  3. 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.

  4. Simulation of Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes

    DTIC Science & Technology

    2015-11-01

    Memorandum Simulation of Weld Mechanical Behavior to Include Welding -Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes... Weld Mechanical Behavior to Include Welding -Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes by Charles R. Fisher...TYPE Technical Report 3. DATES COVERED (From - To) Dec 2013 – July 2015 4. TITLE AND SUBTITLE Simulation of Weld Mechanical Behavior to Include

  5. Simulation of Weld Mechanical Behavior to Include Welding Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes

    DTIC Science & Technology

    2015-11-01

    Memorandum Simulation of Weld Mechanical Behavior to Include Welding -Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes... Weld Mechanical Behavior to Include Welding -Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes by Charles R. Fisher...TYPE Technical Report 3. DATES COVERED (From - To) Dec 2013 – July 2015 4. TITLE AND SUBTITLE Simulation of Weld Mechanical Behavior to Include

  6. 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

  7. Thermo-mechanical treatment effects on stress relaxation and hydrogen embrittlement of cold-drawn eutectoid steels

    NASA Astrophysics Data System (ADS)

    Caballero, L.; Atienza, J. M.; Elices, M.

    2011-12-01

    The effects of the temperature and stretching levels used in the stress-relieving treatment of cold-drawn eutectoid steel wires are evaluated with the aim of improving the stress relaxation behavior and the resistance to hydrogen embrittlement. Five industrial treatments are studied, combining three temperatures (330, 400, and 460 °C) and three stretching levels (38, 50 and 64% of the rupture load). The change of the residual stress produced by the treatments is taken into consideration to account for the results. Surface residual stresses allow us to explain the time to failure in standard hydrogen embrittlement tests.

  8. 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.

  9. Alternative Gas Mixtures in Arc Spraying: A Chance to Improve Coating Properties and Residual Stress States

    NASA Astrophysics Data System (ADS)

    Hauer, Michél; Henkel, Knuth Michael; Krebs, Sebastian; Kroemmer, Werner

    2018-01-01

    The highly cavitation erosion-resistant propeller alloys CuAl9Ni5Fe4Mn (Ni-Al-Bronze) and CuMn13Al8Fe3Ni2 (Mn-Al-Bronze) were arc-sprayed using a mixture of nitrogen and 2% of hydrogen as atomizing gas and different traverse speeds. The objective was to identify the influences of the different spraying conditions, such as temperature regime and melting loss, on the resulting residual stress states and coating properties. Residual stresses were measured by the incremental hole-drilling method using ESPI. Temperature measurements were carried out by thermographic imaging. Microstructural, chemical and mechanical analyses were realized to examine adhesive and cohesive properties. Additionally, the cavitation erosion behavior was investigated to analyze cohesive coating properties. The spraying process itself was improved, which was apparent by mainly enhanced deposition efficiency and reduced surface temperatures. The amount of oxides and pores as well as the melting loss of alloying elements were reduced. Moreover, an increased cavitation erosion resistance and thus coating cohesion as well as less residual stresses were identified. The change in atomizing gas diminished the impact of the quenching stresses on the coating properties. In contrast, the adhesive strength, Young's moduli and partially the hardness were slightly reduced. With regard to materials, Ni-Al-Bronze revealed superior coating properties in comparison with Mn-Al-Bronze.

  10. Main-ion intrinsic toroidal rotation profile driven by residual stress torque from ion temperature gradient turbulence in the DIII-D tokamak

    DOE PAGES

    Grierson, B. A.; Wang, W. X.; Ethier, S.; ...

    2017-01-06

    Intrinsic toroidal rotation of the deuterium main ions in the core of the DIII-D tokamak is observed to transition from flat to hollow, forming an off-axis peak, above a threshold level of direct electron heating. Nonlinear gyrokinetic simulations show that the residual stress associated with electrostatic ion temperature gradient turbulence possesses the correct radial location and stress structure to cause the observed hollow rotation profile. Residual stress momentum flux in the gyrokinetic simulations is balanced by turbulent momentum diffusion, with negligible contributions from turbulent pinch. Finally, the prediction of the velocity profile by integrating the momentum balance equation produces amore » rotation profile that qualitatively and quantitatively agrees with the measured main-ion profile, demonstrating that fluctuation-induced residual stress can drive the observed intrinsic velocity profile.« less

  11. Measuring the residual stress of transparent conductive oxide films on PET by the double-beam shadow Moiré interferometer

    NASA Astrophysics Data System (ADS)

    Chen, Hsi-Chao; Huang, Kuo-Ting; Lo, Yen-Ming; Chiu, Hsuan-Yi; Chen, Guan-Jhen

    2011-09-01

    The purpose of this research was to construct a measurement system which can fast and accurately analyze the residual stress of the flexible electronics. The transparent conductive oxide (TCO) films, tin-doped indium oxide (ITO), were deposited by radio frequency (RF) magnetron sputtering using corresponding oxide targets on PET substrate. As we know that the shadow Moiré interferometry is a useable way to measure the large deformation. So we set up a double beam shadow Moiré interferometer to measure and analyze the residual stress of TCO films on PET. The feature was to develop a mathematical model and combine the image processing software. By the LabVIEW graphical software, we could measure the distance which is between the left and right fringe on the pattern to solve the curvature of deformed surface. Hence, the residual stress could calculate by the Stoney correction formula for the flexible electronics. By combining phase shifting method with shadow Moiré, the measurement resolution and accuracy have been greatly improved. We also had done the error analysis for the system whose relative error could be about 2%. Therefore, shadow Moiré interferometer is a non-destructive, fast, and simple system for the residual stress on TCO/PET films.

  12. From cells to laminate: probing and modeling residual stress evolution in thin silicon photovoltaic modules using synchrotron X-ray micro-diffraction experiments and finite element simulations

    DOE PAGES

    Tippabhotla, Sasi Kumar; Radchenko, Ihor; Song, W. J. R.; ...

    2017-04-12

    Fracture of silicon crystalline solar cells has recently been observed in increasing percentages especially in solar photovoltaic (PV) modules involving thinner silicon solar cells (<200 μm). Many failures due to fracture have been reported from the field because of environmental loading (snow, wind, etc.) as well as mishandling of the solar PV modules (during installation, maintenance, etc.). However, a significantly higher number of failures have also been reported during module encapsulation (lamination) indicating high residual stress in the modules and thus more prone to cell cracking. Here in this paper we report through the use of synchrotron X-ray submicron diffractionmore » coupled with physics-based finite element modeling, the complete residual stress evolution in mono-crystalline silicon solar cells during PV module integration process. For the first time, we unravel the reason for the high stress and cracking of silicon cells near soldered inter-connects. Our experiments revealed a significant increase of residual stress in the silicon cell near the solder joint after lamination. Moreover, our finite element simulations show that this increase of stress during lamination is a result of highly localized bending of the cell near the soldered inter-connects. Further, the synchrotron X-ray submicron diffraction has proven to be a very effective way to quantitatively probe mechanical stress in encapsulated silicon solar cells. Thus, this technique has ultimately enabled these findings leading to the enlightening of the role of soldering and encapsulation processes on the cell residual stress. This model can be further used to suggest methodologies that could lead to lower stress in encapsulated silicon solar cells, which are the subjects of our continued investigations.« less

  13. From cells to laminate: probing and modeling residual stress evolution in thin silicon photovoltaic modules using synchrotron X-ray micro-diffraction experiments and finite element simulations

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Tippabhotla, Sasi Kumar; Radchenko, Ihor; Song, W. J. R.

    Fracture of silicon crystalline solar cells has recently been observed in increasing percentages especially in solar photovoltaic (PV) modules involving thinner silicon solar cells (<200 μm). Many failures due to fracture have been reported from the field because of environmental loading (snow, wind, etc.) as well as mishandling of the solar PV modules (during installation, maintenance, etc.). However, a significantly higher number of failures have also been reported during module encapsulation (lamination) indicating high residual stress in the modules and thus more prone to cell cracking. Here in this paper we report through the use of synchrotron X-ray submicron diffractionmore » coupled with physics-based finite element modeling, the complete residual stress evolution in mono-crystalline silicon solar cells during PV module integration process. For the first time, we unravel the reason for the high stress and cracking of silicon cells near soldered inter-connects. Our experiments revealed a significant increase of residual stress in the silicon cell near the solder joint after lamination. Moreover, our finite element simulations show that this increase of stress during lamination is a result of highly localized bending of the cell near the soldered inter-connects. Further, the synchrotron X-ray submicron diffraction has proven to be a very effective way to quantitatively probe mechanical stress in encapsulated silicon solar cells. Thus, this technique has ultimately enabled these findings leading to the enlightening of the role of soldering and encapsulation processes on the cell residual stress. This model can be further used to suggest methodologies that could lead to lower stress in encapsulated silicon solar cells, which are the subjects of our continued investigations.« less

  14. Deposition stress effects on thermal barrier coating burner rig life

    NASA Technical Reports Server (NTRS)

    Watson, J. W.; Levine, S. R.

    1984-01-01

    A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

  15. The relation between residual stress, interfacial structure and the joint property in the SiO2f/SiO2-Nb joints.

    PubMed

    Ma, Qiang; Li, Zhuo Ran; Yang, Lai Shan; Lin, Jing Huang; Ba, Jin; Wang, Ze Yu; Qi, Jun Lei; Feng, Ji Cai

    2017-06-23

    In order to achieve a high-quality joint between SiO 2f /SiO 2 and metals, it is necessary to address the poor wettability of SiO 2f /SiO 2 and the high residual stress in SiO 2f /SiO 2 -Nb joint. Here, we simultaneously realize good wettability and low residual stress in SiO 2f /SiO 2 -Nb joint by combined method of HF etching treatment and Finite Element Analysis (FEA). After etching treatment, the wettability of E-SiO 2f /SiO 2 was improved, and the residual stress in the joint was decreased. In order to better control the quality of joints, efforts were made to understand the relationship between surface structure of E-SiO 2f /SiO 2 and residual stress in joint using FEA. Based on the direction of FEA results, a relationship between residual stress, surface structure and joint property in the brazed joints were investigated by experiments. As well the FEA and the brazing test results both realized the high-quality joint of E-SiO 2f /SiO 2 -Nb and the shear strength of the joint reached 61.9 MPa.

  16. The generation of thermal stress and strain during quenching

    NASA Astrophysics Data System (ADS)

    Soomro, A. B.

    A viscoelastic-plastic mathematical model was used to calculate the thermal stress and strain generated during the quenching of an infinite plate of high hardenability steel (835M30) in water, oil and Polymer. In the present work the mathematical model was modified to include the effect of initial stress on the rate of stress relaxation, which has been found to be significant. The data required to incorporate this effect into the calculations, were obtained experimentally during the-.present investigation. The effect of an applied stress during transformation (transformation plasticity) was also introduced in the mathematical model. The new model produced a marked improvement in the degree of agreement between the calculated and experimental residual stress, although the corresponding level of agreement in the case of residual strain was less good. In particular, strains after water quenching agreed less well with experiment as a consequence of the change in the model, although this drawback was not found after oil and polymer quenching. The new mathematical model was used to investigate the effect of martempering, section size and transformation temperature range on the generation of thermal stress and strain. A salt bath treatment above the Ms temperature followed by air cooling prevented residual stress development, but an oil quench after the salt bath treatment generated a level of residual stress at the end of cooling that was similar to that obtained after a direct oil quench from 850°C. Neither martempering process was successful in reducing residual strain.With.an increase in section size a reduction in the residual stress and an increase in the distortions was obtained after a water quench. However, after oil quenching the overall effect of section size on residual stress and strain was small. The effect of variation in the transformation temperature range was found to be small in the case of residual stress but an increase in Ms temperature produced a

  17. Intrinsic rotation from a residual stress at the boundary of a cylindrical laboratory plasma.

    PubMed

    Yan, Z; Xu, M; Diamond, P H; Holland, C; Müller, S H; Tynan, G R; Yu, J H

    2010-02-12

    An azimuthally symmetric radially sheared azimuthal flow is driven by a nondiffusive, or residual, turbulent stress localized to a narrow annular region at the boundary of a cylindrical magnetized helicon plasma device. A no-slip condition, imposed by ion-neutral flow damping outside the annular region, combined with a diffusive stress arising from turbulent and collisional viscous damping in the central plasma region, leads to net plasma rotation in the absence of momentum input.

  18. Effects of mechanical and thermal cycling on composite and hybrid laminates with residual stresses

    NASA Technical Reports Server (NTRS)

    Daniel, I. M.; Liber, T.

    1977-01-01

    The effects of tensile load cycling and thermal cycling on residual stiffness and strength properties of the following composite and hybrid angle-ply laminates were studied: boron/epoxy, boron/polyimide, graphite/low-modulus epoxy, graphite/high-modulus epoxy, graphite/polyimide, S-glass/epoxy, graphite/Kevlar 49/epoxy, and graphite/S-glass/epoxy. Specimens of the first six types were mechanically cycled up to 90% of static strength. Those that survived 10 million cycles were tested statically to failure, and no significant changes in residual strength and modulus were noted. Specimens of all types were subjected to thermal cycling between room temperature and 411 K for the epoxy-matrix composites and 533 K for the polyimide-matrix composites. The residual strength and stiffness remained largely unchanged, except for the graphite/low-modulus epoxy, which showed reductions in both of approximately 35%. When low-temperature thermal cycling under tensile load was applied, there was a noticeable reduction in modulus and strength in the graphite/low-modulus epoxy and some strength reduction in the S-glass/epoxy.

  19. Salinity stress accelerates the effect of cadmium toxicity on soil N dynamics and cycling: Does joint effect of these stresses matter?

    PubMed

    Raiesi, Fayez; Razmkhah, Mahshid; Kiani, Shahram

    2018-05-30

    The objective of this study was to determine responses of soil nitrogen (N) transformation, microbial biomass N, and urease activity to the combined effect of cadmium (Cd) toxicity (0 and 30 mg kg -1 ) and NaCl stress (0, 7.5 and 15 dS m -1 ) in a clay loam soil unamended (0%) or amended with alfalfa residues (1%, w/w). Cd, NaCl, and alfalfa residues were added to the soil, and the mixtures were incubated for 90 days under standard laboratory conditions (25 ± 1 °C and 70% of water holding capacity [WHC]). The results showed that salinity increased soil Cd availability and toxicity and subsequently decreased soil microbial N transformations (i.e., potential ammonification and nitrification as well as net N mineralization), arginine ammonification and nitrification rates, microbial biomass N, and urease activity. The adverse effects of salinity on soil microbial properties were greater in Cd-polluted than unpolluted soils, at high than low salinity levels, but were lower in residue-amended than unamended soils. These effects were mainly attributed to the increased Cd availability under saline conditions or the decreased Cd availability with residue addition. All the measured soil microbial attributes showed a negative correlation with the available Cd content in the soil. The interaction or combined effects of Cd and NaCl on soil microbial attributes were mostly synergistic in residue-unamended soils but antagonistic in residue-amended soils. The addition of organic residues to Cd-polluted soils may moderate salinity effect, and thus could stimulate the activity of ammonifiers and nitrifiers, as well as urease. Copyright © 2018 Elsevier Inc. All rights reserved.

  20. Thermoelastic Stress Analysis: The Mean Stress Effect in Metallic Alloys

    NASA Technical Reports Server (NTRS)

    Gyekenyesi, Andrew L.; Baaklini, George Y.

    1999-01-01

    The primary objective of this study involved the utilization of the thermoelastic stress analysis (TSA) method to demonstrate the mean stress dependence of the thermoelastic constant. Titanium and nickel base alloys, commonly employed in aerospace gas turbines, were the materials of interest. The repeatability of the results was studied through a statistical analysis of the data. Although the mean stress dependence was well established, the ability to confidently quantify it was diminished by the experimental variations. If calibration of the thermoelastic response to mean stress can be successfully implemented, it is feasible to use the relationship to determine a structure's residual stress state.

  1. 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.

  2. Effects of Recovery Behavior and Strain-Rate Dependence of Stress-Strain Curve on Prediction Accuracy of Thermal Stress Analysis During Casting

    NASA Astrophysics Data System (ADS)

    Motoyama, Yuichi; Shiga, Hidetoshi; Sato, Takeshi; Kambe, Hiroshi; Yoshida, Makoto

    2017-06-01

    Recovery behavior (recovery) and strain-rate dependence of the stress-strain curve (strain-rate dependence) are incorporated into constitutive equations of alloys to predict residual stress and thermal stress during casting. Nevertheless, few studies have systematically investigated the effects of these metallurgical phenomena on the prediction accuracy of thermal stress in a casting. This study compares the thermal stress analysis results with in situ thermal stress measurement results of an Al-Si-Cu specimen during casting. The results underscore the importance for the alloy constitutive equation of incorporating strain-rate dependence to predict thermal stress that develops at high temperatures where the alloy shows strong strain-rate dependence of the stress-strain curve. However, the prediction accuracy of the thermal stress developed at low temperatures did not improve by considering the strain-rate dependence. Incorporating recovery into the constitutive equation improved the accuracy of the simulated thermal stress at low temperatures. Results of comparison implied that the constitutive equation should include strain-rate dependence to simulate defects that develop from thermal stress at high temperatures, such as hot tearing and hot cracking. Recovery should be incorporated into the alloy constitutive equation to predict the casting residual stress and deformation caused by the thermal stress developed mainly in the low temperature range.

  3. A mechanical analysis of conduit arteries accounting for longitudinal residual strains.

    PubMed

    Wang, Ruoya; Gleason, Rudolph L

    2010-04-01

    Identification of an appropriate stress-free reference configuration is critically important in providing a reasonable prediction of the intramural stress distribution when performing biomechanical analyses on arteries. The stress-free state is commonly approximated as a radially cut ring that typically opens into a nearly circular sector, relieving much of the circumferential residual strains that exist in the traction-free configuration. An opening angle is often used to characterize this sector. In this study, we first present experimental results showing significant residual deformations in the longitudinal direction of two commonly studied arteries in the pig: the common carotid artery and the left anterior descending coronary artery. We concluded that a radially cut ring cannot completely describe the stress-free state of the arteries. Instead, we propose the use of a longitudinal opening angle, in conjunction with the traditional circumferential opening angle, to experimentally quantify the stress-free state of an artery. Secondly, we propose a new kinematic model to account for the addition of longitudinal residual strains through employing the longitudinal opening angle and performed a stress analysis. We found that with the inclusion of longitudinal residual strains in the stress analysis, the predicted circumferential stress gradient was decreased by 3-fold and the predicted longitudinal stress gradient was increased by 5.7-fold. Thus, inclusion of longitudinal residual strains has a significant effect on the predicted stress distribution in arteries.

  4. An Assessment of Subsurface Residual Stress Analysis in SLM Ti-6Al-4V

    PubMed Central

    Mishurova, Tatiana; Cabeza, Sandra; Artzt, Katia; Haubrich, Jan; Klaus, Manuela; Genzel, Christoph; Requena, Guillermo; Bruno, Giovanni

    2017-01-01

    Ti-6Al-4V bridges were additively fabricated by selective laser melting (SLM) under different scanning speed conditions, to compare the effect of process energy density on the residual stress state. Subsurface lattice strain characterization was conducted by means of synchrotron diffraction in energy dispersive mode. High tensile strain gradients were found at the frontal surface for samples in an as-built condition. The geometry of the samples promotes increasing strains towards the pillar of the bridges. We observed that the higher the laser energy density during fabrication, the lower the lattice strains. A relief of lattice strains takes place after heat treatment. PMID:28772706

  5. 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.

  6. 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

  7. Effects of welding technology on welding stress based on the finite element method

    NASA Astrophysics Data System (ADS)

    Fu, Jianke; Jin, Jun

    2017-01-01

    Finite element method is used to simulate the welding process under four different conditions of welding flat butt joints. Welding seams are simulated with birth and death elements. The size and distribution of welding residual stress is obtained in the four kinds of welding conditions by Q345 manganese steel plate butt joint of the work piece. The results shown that when using two-layers welding,the longitudinal and transverse residual stress were reduced;When welding from Middle to both sides,the residual stress distribution will change,and the residual stress in the middle of the work piece was reduced.

  8. Influence of Residual Stresses on Fretting Fatigue Life Prediction in Ti-6Al-4V (POSTPRINT)

    DTIC Science & Technology

    2008-01-01

    DATE (DD-MM-YY) 2. REPORT TYPE 3. DATES COVERED (From - To) January 2008 Journal Article Postprint 4 . TITLE AND SUBTITLE INFLUENCE OF RESIDUAL...62102F 6 . AUTHOR(S) Patrick J. Golden (AFRL/RXLMN) Dennis Buchanan (University of Dayton Research Institute) Sam Naboulsi (The University of...induced compressive residual stresses by methods such as shot-peening could also be disrupted by this plasticity. Manuscript received December 4 , 2007

  9. Residual Stresses in Thermal Barrier Coatings for a Cu-8Cr-4Nb Substrate System

    NASA Technical Reports Server (NTRS)

    Ghosn, Louis J.; Raj, Sai V.

    2002-01-01

    Analytical calculations were conducted to determine the thermal stresses developed in a coated copper-based alloy, Cu-8%(at.%)Cr-4%Nb (designated as GRCop-84), after plasma spraying and during heat-up in a simulated rocket engine environment. Finite element analyses were conducted for two coating systems consisting of a metallic top coat, a pure copper bond coat and the GRCop-84. The through thickness temperature variations were determined as a function of coating thickness for two metallic coatings, a Ni-17%(wt%)Cr-6%Al-0.5%Y alloy and a Ni-50%(at.%)Al alloy. The residual stresses after low-pressure plasma spraying of the NiCrAlY and NiAl coatings on GRCop-84 substrate were also evaluated. These analyses took into consideration a 50.8 mm copper bond coat and the effects of an interface coating roughness. The through the thickness thermal stresses developed in coated liners were also calculated after 15 minutes of exposure in a rocket environment with and without an interfacial roughness.

  10. Residual stress analysis on AA6061+22% Al2O3p simple shape demonstrators of a wheel hub

    NASA Astrophysics Data System (ADS)

    Giuliani, Alessandra; Albertini, Gianni; Fiori, Fabrizio; Girardin, Emmanuelle

    2004-07-01

    The effects of thermal treatments in a component for automotive industry are considered: the induced residual stresses in wheel hubs were investigated. Measurements have been carried out on two identical simple shape demonstrators made of AA6061+22% Al2O3p in order to evaluate the stress conditions after forging and T6 treatment and without taking into account the final design of the wheel hub. One sample was analysed in as-forged conditions while the second after forging and T6 treatment (560°C for 2h, 20°C water quenching, artificial aging at 177°C for 10h). Particular attention was given to the stresses in the radial and hoop directions, as the main consequences of the in-service fatigue are expected to be related to stresses along these two directions.

  11. Design of low surface roughness-low residual stress-high optoelectronic merit a-IZO thin films for flexible OLEDs

    DOE PAGES

    Kumar, Naveen; Wilkinson, Taylor M.; Packard, Corinne E.; ...

    2016-06-08

    The development of efficient and reliable large-area flexible optoelectronic devices demands low surface roughness-low residual stress-high optoelectronic merit transparent conducting oxide (TCO) thin films. Here, we correlate surface roughness-residual stress-optoelectronic properties of sputtered amorphous indium zinc oxide (a-IZO) thin films using a statistical design of experiment (DOE) approach and find a common growth space to achieve a smooth surface in a stress-free and high optoelectronic merit a-IZO thin film. The sputtering power, growth pressure, oxygen partial pressure, and RF/(RF+DC) are varied in a two-level system with a full factorial design, and results are used to deconvolve the complex growth space,more » identifying significant control growth parameters and their possible interactions. The surface roughness of a-IZO thin film varies over 0.19 nm to 3.97 nm, which is not in line with the general assumption of low surface roughness in a-IZO thin films. The initial regression model and analysis of variance reveal no single optimum growth sub-space to achieve low surface roughness (=0.5 nm), low residual stress (-1 to 0 GPa), and industrially acceptable electrical conductivity (>1000 S/cm) for a-IZO thin films. The extrapolation of growth parameters in light of the current results and previous knowledge leads to a new sub-space, resulting in a low residual stress of -0.52 +/- 0.04 GPa, a low surface roughness of 0.55 +/- 0.03 nm, and moderate electrical conductivity of 1962 +/- 3.84 S/cm in a-IZO thin films. Lastly, these results demonstrate the utility of the DOE approach to multi-parameter optimization, which provides an important tool for the development of flexible TCOs for the next-generation flexible organic light emitting diodes applications.« less

  12. Design of low surface roughness-low residual stress-high optoelectronic merit a-IZO thin films for flexible OLEDs

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kumar, Naveen; Kumar, Mukesh, E-mail: mkumar@iitrpr.ac.in, E-mail: cpackard@mines.edu; Wilkinson, Taylor M.

    2016-06-14

    The development of efficient and reliable large-area flexible optoelectronic devices demands low surface roughness-low residual stress-high optoelectronic merit transparent conducting oxide (TCO) thin films. Here, we correlate surface roughness-residual stress-optoelectronic properties of sputtered amorphous indium zinc oxide (a-IZO) thin films using a statistical design of experiment (DOE) approach and find a common growth space to achieve a smooth surface in a stress-free and high optoelectronic merit a-IZO thin film. The sputtering power, growth pressure, oxygen partial pressure, and RF/(RF+DC) are varied in a two-level system with a full factorial design, and results are used to deconvolve the complex growth space,more » identifying significant control growth parameters and their possible interactions. The surface roughness of a-IZO thin film varies over 0.19 nm to 3.97 nm, which is not in line with the general assumption of low surface roughness in a-IZO thin films. The initial regression model and analysis of variance reveal no single optimum growth sub-space to achieve low surface roughness (≤0.5 nm), low residual stress (−1 to 0 GPa), and industrially acceptable electrical conductivity (>1000 S/cm) for a-IZO thin films. The extrapolation of growth parameters in light of the current results and previous knowledge leads to a new sub-space, resulting in a low residual stress of −0.52±0.04 GPa, a low surface roughness of 0.55±0.03 nm, and moderate electrical conductivity of 1962±3.84 S/cm in a-IZO thin films. These results demonstrate the utility of the DOE approach to multi-parameter optimization, which provides an important tool for the development of flexible TCOs for the next-generation flexible organic light emitting diodes applications.« less

  13. 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.

  14. Residual Stress Distribution and Microstructure of a Multiple Laser-Peened Near-Alpha Titanium Alloy

    NASA Astrophysics Data System (ADS)

    Umapathi, A.; Swaroop, S.

    2018-04-01

    Laser peening without coating (LPwC) was performed on a Ti-2.5 Cu alloy with multiple passes (1, 3 and 5), using a Nd:YAG laser (1064 nm) at a constant overlap rate of 70% and power density of 6.7 GW cm-2. Hardness and residual stress profiles indicated thermal softening near the surface (< 100 μm) and bulk softening due to adiabatic heating. Maximum hardness (235 HV at 500 μm) and maximum residual stress (- 890 MPa at 100 μm) were observed for LPwC with 1 pass. Surface roughness and surface 3-D topography imaging showed that the surface roughness increased with the increase in the number of passes. XRD results indicated no significant β phases. However, peak shifts, broadening and asymmetry were observed and interpreted based on dislocation activity. Microstructures indicated no melting or resolidification or refinement of grains at the surface. Twin density was found to increase with the increase in the number of passes.

  15. Residual Stress Distribution and Microstructure of a Multiple Laser-Peened Near-Alpha Titanium Alloy

    NASA Astrophysics Data System (ADS)

    Umapathi, A.; Swaroop, S.

    2018-05-01

    Laser peening without coating (LPwC) was performed on a Ti-2.5 Cu alloy with multiple passes (1, 3 and 5), using a Nd:YAG laser (1064 nm) at a constant overlap rate of 70% and power density of 6.7 GW cm-2. Hardness and residual stress profiles indicated thermal softening near the surface (< 100 μm) and bulk softening due to adiabatic heating. Maximum hardness (235 HV at 500 μm) and maximum residual stress (- 890 MPa at 100 μm) were observed for LPwC with 1 pass. Surface roughness and surface 3-D topography imaging showed that the surface roughness increased with the increase in the number of passes. XRD results indicated no significant β phases. However, peak shifts, broadening and asymmetry were observed and interpreted based on dislocation activity. Microstructures indicated no melting or resolidification or refinement of grains at the surface. Twin density was found to increase with the increase in the number of passes.

  16. Evaluating the damage of steel 09G2S under static and cyclic loading with regard for the level of residual stresses in the metal

    NASA Astrophysics Data System (ADS)

    Kuznetsov, A. V.; Kamantsev, I. S.; Zadvorkin, S. M.; Drukarenko, N. A.; Goruleva, L. S.; Veselova, V. E.

    2017-12-01

    An approach to the estimation of the residual durability of structural elements in view of their initial stress-strain state is proposed. The adequacy of the developed approach is confirmed by experiments on cyclic loading of specimens without pronounced stress concentrators simulating the work of real structural elements under conditions of overshooting the total stresses causing local plastic deformation of the material, with regard for residual stresses.

  17. Effect of additives on the tensile performance and protein solubility of industrial oilseed residual based plastics.

    PubMed

    Newson, William R; Kuktaite, Ramune; Hedenqvist, Mikael S; Gällstedt, Mikael; Johansson, Eva

    2014-07-16

    Ten chemical additives were selected from the literature for their proposed modifying activity in protein-protein interactions. These consisted of acids, bases, reducing agents, and denaturants and were added to residual deoiled meals of Crambe abyssinica (crambe) and Brassica carinata (carinata) to modify the properties of plastics produced through hot compression molding at 130 °C. The films produced were examined for tensile properties, protein solubility, molecular weight distribution, and water absorption. Of the additives tested, NaOH had the greatest positive effect on tensile properties, with increases of 105% in maximum stress and 200% in strain at maximum stress for crambe and a 70% increase in strain at maximum stress for carinata. Stiffness was not increased by any of the applied additives. Changes in tensile strength and elongation for crambe and elongation for carinata were related to changes in protein solubility. Increased pH was the most successful in improving the protein aggregation and mechanical properties within the complex chemistry of residual oilseed meals.

  18. Residual stress determination of direct metal laser sintered (DMLS) inconel specimens and parts

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Watkins, Thomas R.; Unocic, Kinga A.; Maziasz, Philip J.

    Residual stress determinations and microstructural studies were performed on a series of Inconel 718Plus prisms built using Direct Metal Laser Sintering (DMLS) at Honeywell Aerospace (hereafter also referred to as Honeywell). The results are being used to validate and improve existing models at Honeywell, and ultimately will expedite the implementation of DMLS throughout various industrial sectors (automotive, biomedical, etc.).

  19. Numerical analysis of residual stresses in preforms of stress applying part for PANDA-type polarization maintaining optical fibers in view of technological imperfections of the doped zone geometry

    NASA Astrophysics Data System (ADS)

    Trufanov, Aleksandr N.; Trufanov, Nikolay A.; Semenov, Nikita V.

    2016-09-01

    The experimental data analysis of the stress applying rod section geometry for the PANDA-type polarization maintaining optical fiber has been performed. The dependencies of the change in the radial dimensions of the preform and the doping boundary on the angular coordinate have been obtained. The original algorithm of experimental data statistic analysis, which enables determination of the specimens' characteristic form of section, has been described. The influence of actual doped zone geometry on the residual stress fields formed during the stress rod preform fabrication has been investigated. It has been established that the deviation of the boundary between pure silica and the doped zone from the circular shape results in dissymmetry and local concentrations of the residual stress fields along the section, which can cause preforms destruction at high degrees of doping. The observed geometry deviations of up to 10% lead to the increase of the maximum stress intensity value by over 20%.

  20. Microstructure and Residual Stress Distributions Under the Influence of Welding Speed in Friction Stir Welded 2024 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Moghadam, Danial Ghahremani; Farhangdoost, Khalil; Nejad, Reza Masoudi

    2016-06-01

    Friction stir welding was conducted on 8-mm-thick plates made of AA2024-T351 aluminum alloy at tool traverse speeds between 8 and 31.5 mm/minutes and tool rotational speed between 400 and 800 rpm. Metallographic analyses and mechanical tests including hardness, tensile, residual stress, and fracture toughness tests were carried out to evaluate the microstructural and mechanical properties of the joints as a function of the process parameters. The finite element simulation of the FSW process was also performed using a thermal model. The hardness test results show that the increase in rotational speed or decrease in traverse speed of the tool would cause a decrease in weld zone hardness. The best tensile properties are obtained at rotational/traverse speed ratio between 20 and 32. Also, the longitudinal residual stress profiles were evaluated by employing X-ray diffraction method. The numerical and experimental results showed that the increase in a traverse or rotational speed would increase the residual stress of the weld zone. From the fracture toughness results, it was found that the welding process decreases the joints fracture toughness 18 to 49 pct with respect to the base metal.

  1. Evolution of microstructure and residual stress during annealing of austenitic and ferritic steels

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Wawszczak, R.; Baczmański, A., E-mail: Andrzej.Baczmanski@fis.agh.edu.pl; Marciszko, M.

    2016-02-15

    In this work the recovery and recrystallization processes occurring in ferritic and austenitic steels were studied. To determine the evolution of residual stresses during material annealing the nonlinear sin{sup 2}ψ diffraction method was used and an important relaxation of the macrostresses as well as the microstresses was found in the cold rolled samples subjected to heat treatment. Such relaxation occurs at the beginning of recovery, when any changes of microstructure cannot be detected using other experimental techniques. Stress evolution in the annealed steel samples was correlated with the progress of recovery process, which significantly depends on the value of stackingmore » fault energy. - Highlights: • X-ray diffraction was used to determine the first order and second order stresses. • Diffraction data were analyzed using scale transition elastoplastic models model. • Stress relaxation in annealed ferritic and austenitic steels was correlated with evolution of microstructure. • Influence of stacking fault energy on thermally induced processes was discussed.« less

  2. 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.

  3. Vibration stress relief of DH 36 rectangle welded plates

    NASA Astrophysics Data System (ADS)

    Li, Shuqi; Fang, Hongyuan

    2018-03-01

    Vibration stress relief (VSR) is widely used in reducing residual stress in welded structures. However, the effectiveness of this method is still instable in some circumstance. In this study, a covert negative treatment phenomenon was investigated, i.e. natural frequency of welded structures decreased after VSR but residual stress in one direction increased. When the alteration of natural frequency after VSR is significant, the residual stresses in both the longitudinal and transversal directions shall decrease. Otherwise, residual stresses may increase on one direction. Thus, sufficient power shall be applied to the welded structures to avoid negative results.

  4. Simulation investigation of thermal phase transformation and residual stress in single pulse EDM of Ti-6Al-4V

    NASA Astrophysics Data System (ADS)

    Tang, Jiajing; Yang, Xiaodong

    2018-04-01

    The thermal phase transformation and residual stress are ineluctable in the electrical discharge machining (EDM) process, and they will greatly affect the working performances of the machined surface. This paper presents a simulation study on the thermal phase transformation and residual stress in single-pulse EDM of Ti-6Al-4V, which is the most popular titanium alloy in fields such as aircraft engine and some other leading industries. A multi-physics model including thermal, hydraulic, metallography and structural mechanics was developed. Based on the proposed model, the thickness and metallographic structure of the recast layer and heat affected layer (HAZ) were investigated. The distribution and characteristics of residual stress around the discharge crater were obtained. The recast layer and HAZ at the center of crater are found to be the thinnest, and their thicknesses gradually increase approaching the periphery of the crater. The recast layer undergoes a complete α‧ (martensitic) transformation, while the HAZ is mainly composed by the α  +  β  +  α‧ three-phase microstructure. Along the depth direction of crater, the Von Mises stress increases first and then decreases, reaching its maximal value near the interface of recast layer and HAZ. In the recast layer, both compressive stress component and tensile stress component are observed. ANOVA results showed that the influence of discharge current on maximal tensile stress is more significant than that of pulse duration, while the pulse duration has more significant influence on average thickness of the recast layer and the depth location of the maximal tensile stress. The works conducted in this study will help to evaluate the quality and integrity of EDMed surface, especially when the non-destructive testing is difficult to achieve.

  5. 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

  6. Numerical and experimental analysis for solidification and residual stress in the GMAW process for AISI 304 stainless steel

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Choi, J.; Mazumder, J.

    1996-12-31

    Networking three fields of welding--thermal, microstructure, and stress--was attempted and produced a reliable model using a numerical method with the finite element analysis technique. Model prediction was compared with experimental data in order to validate the model. The effects of welding process parameters on these welding fields were analyzed and reported. The effort to correlate the residual stress and solidification was initiated, with some valuable results. The solidification process was simulated using the formulation based on the Hunt-Trivedi model. Based on the temperature history, solidification speed and primary dendrite arm spacing were predicted at given nodes of interest. Results showmore » that the variation during solidification is usually within an order of magnitude. The temperature gradient was generally in the range of 10{sup 4}--10{sup 5} K/m for the given welding conditions (welding power = 6 kW and welding speed = 3.3867 to 7.62 mm/sec), while solidification speed appeared to slow down from an order of 10{sup {minus}1} to 10{sup {minus}2} m/sec during solidification. SEM images revealed that the primary dendrite arm spacing (PDAS) fell in the range of 10{sup 1}--10{sup 2} {micro}m. For grain growth at the heat affected zone (HAZ), Ashby`s model was employed. The prediction was in agreement with experimental results. For the residual stress calculation, the same mesh generation used in the heat transfer analysis was applied to make the simulation consistent. The analysis consisted of a transient heat analysis followed by a thermal stress analysis. An experimentally measured strain history was compared with the simulated result. The relationship between microstructure and the stress/strain field of welding was also obtained. 64 refs., 18 figs., 9 tabs.« less

  7. Residual stress and crack initiation in laser clad composite layer with Co-based alloy and WC + NiCr

    NASA Astrophysics Data System (ADS)

    Lee, Changmin; Park, Hyungkwon; Yoo, Jaehong; Lee, Changhee; Woo, WanChuck; Park, Sunhong

    2015-08-01

    Although laser cladding process has been widely used to improve the wear and corrosion resistance, there are unwanted cracking issues during and/or after laser cladding. This study investigates the tendency of Co-based WC + NiCr composite layers to cracking during the laser cladding process. Residual stress distributions of the specimen are measured using neutron diffraction and elucidate the correlation between the residual stress and the cracking in three types of cylindrical specimens; (i) no cladding substrate only, (ii) cladding with 100% stellite#6, and (iii) cladding with 55% stellite#6 and 45% technolase40s. The microstructure of the clad layer was composed of Co-based dendrite and brittle eutectic phases at the dendritic boundaries. And WC particles were distributed on the matrix forming intermediate composition region by partial melting of the surface of particles. The overlaid specimen exhibited tensile residual stress, which was accumulated through the beads due to contraction of the coating layer generated by rapid solidification, while the non-clad specimen showed compressive. Also, the specimen overlaid with 55 wt% stellite#6 and 45 wt% technolase40s showed a tensile stress higher than the specimen overlaid with 100% stellite#6 possibly, due to the difference between thermal expansion coefficients of the matrix and WC particles. Such tensile stresses can be potential driving force to provide an easy crack path ways for large brittle fractures combined with the crack initiation sites such as the fractured WC particles, pores and solidification cracks. WC particles directly caused clad cracks by particle fracture under the tensile stress. The pores and solidification cracks also affected as initiation sites and provided an easy crack path ways for large brittle fractures.

  8. Acoustoelastic effect of textured (Ba,Sr)TiO{sub 3} thin films under an initial mechanical stress

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kamel, Marwa; Mseddi, Souhir; Njeh, Anouar

    Acoustoelastic (AE) analysis of initial stresses plays an important role as a nondestructive tool in current engineering. Two textured BST (Ba{sub 0.65}Sr{sub 0.35}TiO{sub 3}) thin films, with different substrate to target distance, were grown on Pt(111)/TiO{sub 2}/SiO{sub 2}/Si(001) substrate by rf-magnetron sputtering deposition techniques. A conventional “sin{sup 2} ψ” method to determine residual stress and strain in BST films by X-ray diffraction is applied. A laser acoustic waves (LA-waves) technique is used to generate surface acoustic waves (SAW) propagating in both samples. Young's modulus E and Poisson ratio ν of BST films in different propagation directions are derived from the measuredmore » dispersion curves. Estimation of effective second-order elastic constants of BST thin films in stressed states is served in SAW study. This paper presents an original investigation of AE effect in prestressed Ba{sub 0.65}Sr{sub 0.35}TiO{sub 3} films, where the effective elastic constants and the effect of texture on second and third order elastic tensor are considered and used. The propagation behavior of Rayleigh and Love waves in BST thin films under residual stress is explored and discussed. The guiding velocities affected by residual stresses, reveal some shifts which do not exceed four percent mainly in the low frequency range.« less

  9. Influence of residual welding stresses, overload and specimen preparation on fatigue crack growth under axial compression

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Greasley, A.

    1995-02-01

    Double edge notched axial compression specimens taken from thick welded steel joints have been used to grow fatigue cracks under pulsating compressive loads at mean stresses up to 55% of that needed for general yielding. The redistribution of residual stresses during specimen preparation and during crack growth influences the nucleation, growth rate and extent of fatigue cracks. Crack growth rates which are comparable to the equivalent tensile situation have been observed in as-welded, welded plus overloaded and stress relieved plus overloaded joints. Multiple nucleation and curved crack profiles have been observed in all cases. 5 refs.

  10. Study of Residual Stresses and Distortion in Structural Weldments in High-Strength Steels.

    DTIC Science & Technology

    1982-11-30

    02139 II. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE Department of the Navy November 30, 1982 Office of Naval Research 13. NUMBER OF PAGES...Arlington, Virginia 22217 14. MONITORING AGENCY NAME & ADDRESS(if different from Controlling Office) 15. SECURITY CLASS. (of this report) Unclassified 15a...a residual stress field were calculated. Finally, results from all of the afLrementioned analyses were compared with data obtained from experimental

  11. 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.

  12. Flaw Stability Considering Residual Stress for Aging Management of Spent Nuclear Fuel Multiple-Purpose Canisters

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Lam, Poh-Sang; Sindelar, Robert L.

    A typical multipurpose canister (MPC) is made of austenitic stainless steel and is loaded with spent nuclear fuel assemblies. Because heat treatment for stress relief is not required for the construction of the MPC, the canister is susceptible to stress corrosion cracking in the weld or heat affected zone regions under long-term storage conditions. Logic for flaw acceptance is developed should crack-like flaws be detected by Inservice Inspection. The procedure recommended by API 579-1/ASME FFS-1, Fitness-for-Service, is used to calculate the instability crack length or depth by failure assessment diagram. It is demonstrated that the welding residual stress has amore » strong influence on the results.« less

  13. Flaw Stability Considering Residual Stress for Aging Management of Spent Nuclear Fuel Multiple-Purpose Canisters

    DOE PAGES

    Lam, Poh-Sang; Sindelar, Robert L.

    2016-04-28

    A typical multipurpose canister (MPC) is made of austenitic stainless steel and is loaded with spent nuclear fuel assemblies. Because heat treatment for stress relief is not required for the construction of the MPC, the canister is susceptible to stress corrosion cracking in the weld or heat affected zone regions under long-term storage conditions. Logic for flaw acceptance is developed should crack-like flaws be detected by Inservice Inspection. The procedure recommended by API 579-1/ASME FFS-1, Fitness-for-Service, is used to calculate the instability crack length or depth by failure assessment diagram. It is demonstrated that the welding residual stress has amore » strong influence on the results.« less

  14. Deposition stress effects on the life of thermal barrier coatings on burner rigs

    NASA Technical Reports Server (NTRS)

    Watson, J. W.; Levine, S. R.

    1984-01-01

    A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

  15. Accelerated crack growth, residual stress, and a cracked zinc coated pressure shell

    NASA Technical Reports Server (NTRS)

    Dittman, Daniel L.; Hampton, Roy W.; Nelson, Howard G.

    1987-01-01

    During a partial inspection of a 42 year old, operating, pressurized wind tunnel at NASA-Ames Research Center, a surface connected defect 114 in. long having an indicated depth of a 0.7 in. was detected. The pressure shell, constructed of a medium carbon steel, contains approximately 10 miles of welds and is cooled by flowing water over its zinc coated external surface. Metallurgical and fractographic analysis showed that the actual detect was 1.7 in. deep, and originated from an area of lack of weld penetration. Crack growth studies were performed on the shell material in the laboratory under various loading rates, hold times, and R-ratios with a simulated shell environment. The combination of zinc, water with electrolyte, and steel formed an electrolytic cell which resulted in an increase in cyclic crack growth rate by as much as 500 times over that observed in air. It was concluded that slow crack growth occurred in the pressure shell by a combination of stress corrosion cracking due to the welding residual stress and corrosion fatigue due to the cyclic operating stress.

  16. A Large-scale Finite Element Model on Micromechanical Damage and Failure of Carbon Fiber/Epoxy Composites Including Thermal Residual Stress

    NASA Astrophysics Data System (ADS)

    Liu, P. F.; Li, X. K.

    2018-06-01

    The purpose of this paper is to study micromechanical progressive failure properties of carbon fiber/epoxy composites with thermal residual stress by finite element analysis (FEA). Composite microstructures with hexagonal fiber distribution are used for the representative volume element (RVE), where an initial fiber breakage is assumed. Fiber breakage with random fiber strength is predicted using Monte Carlo simulation, progressive matrix damage is predicted by proposing a continuum damage mechanics model and interface failure is simulated using Xu and Needleman's cohesive model. Temperature dependent thermal expansion coefficients for epoxy matrix are used. FEA by developing numerical codes using ANSYS finite element software is divided into two steps: 1. Thermal residual stresses due to mismatch between fiber and matrix are calculated; 2. Longitudinal tensile load is further exerted on the RVE to perform progressive failure analysis of carbon fiber/epoxy composites. Numerical convergence is solved by introducing the viscous damping effect properly. The extended Mori-Tanaka method that considers interface debonding is used to get homogenized mechanical responses of composites. Three main results by FEA are obtained: 1. the real-time matrix cracking, fiber breakage and interface debonding with increasing tensile strain is simulated. 2. the stress concentration coefficients on neighbouring fibers near the initial broken fiber and the axial fiber stress distribution along the broken fiber are predicted, compared with the results using the global and local load-sharing models based on the shear-lag theory. 3. the tensile strength of composite by FEA is compared with those by the shear-lag theory and experiments. Finally, the tensile stress-strain curve of composites by FEA is applied to the progressive failure analysis of composite pressure vessel.

  17. A Large-scale Finite Element Model on Micromechanical Damage and Failure of Carbon Fiber/Epoxy Composites Including Thermal Residual Stress

    NASA Astrophysics Data System (ADS)

    Liu, P. F.; Li, X. K.

    2017-09-01

    The purpose of this paper is to study micromechanical progressive failure properties of carbon fiber/epoxy composites with thermal residual stress by finite element analysis (FEA). Composite microstructures with hexagonal fiber distribution are used for the representative volume element (RVE), where an initial fiber breakage is assumed. Fiber breakage with random fiber strength is predicted using Monte Carlo simulation, progressive matrix damage is predicted by proposing a continuum damage mechanics model and interface failure is simulated using Xu and Needleman's cohesive model. Temperature dependent thermal expansion coefficients for epoxy matrix are used. FEA by developing numerical codes using ANSYS finite element software is divided into two steps: 1. Thermal residual stresses due to mismatch between fiber and matrix are calculated; 2. Longitudinal tensile load is further exerted on the RVE to perform progressive failure analysis of carbon fiber/epoxy composites. Numerical convergence is solved by introducing the viscous damping effect properly. The extended Mori-Tanaka method that considers interface debonding is used to get homogenized mechanical responses of composites. Three main results by FEA are obtained: 1. the real-time matrix cracking, fiber breakage and interface debonding with increasing tensile strain is simulated. 2. the stress concentration coefficients on neighbouring fibers near the initial broken fiber and the axial fiber stress distribution along the broken fiber are predicted, compared with the results using the global and local load-sharing models based on the shear-lag theory. 3. the tensile strength of composite by FEA is compared with those by the shear-lag theory and experiments. Finally, the tensile stress-strain curve of composites by FEA is applied to the progressive failure analysis of composite pressure vessel.

  18. 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.

  19. 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.

  20. Lateral gradients of phases, residual stress and hardness in a laser heated Ti0.52Al0.48N coating on hard metal

    PubMed Central

    Bartosik, M.; Daniel, R.; Zhang, Z.; Deluca, M.; Ecker, W.; Stefenelli, M.; Klaus, M.; Genzel, C.; Mitterer, C.; Keckes, J.

    2012-01-01

    The influence of a local thermal treatment on the properties of Ti–Al–N coatings is not understood. In the present work, a Ti0.52Al0.48N coating on a WC–Co substrate was heated with a diode laser up to 900 °C for 30 s and radially symmetric lateral gradients of phases, residual stress and hardness were characterized ex-situ using position-resolved synchrotron X-ray diffraction, Raman spectroscopy, transmission electron microscopy and nanoindentation. The results reveal (i) a residual stress relaxation at the edge of the irradiated area and (ii) a compressive stress increase of few GPa in the irradiated area center due to the Ti–Al–N decomposition, in particular due to the formation of small wurtzite (w) AlN domains. The coating hardness increased from 35 to 47 GPa towards the center of the heated spot. In the underlying heated substrate, a residual stress change from about − 200 to 500 MPa down to a depth of 6 μm is observed. Complementary, in-situ high-temperature X-ray diffraction analysis of stresses in a homogeneously heated Ti0.52Al0.48N coating on a WC–Co substrate was performed in the range of 25–1003 °C. The in-situ experiment revealed the origin of the observed thermally-activated residual stress oscillation across the laser heated spot. Finally, it is demonstrated that the coupling of laser heating to produce lateral thermal gradients and position-resolved experimental techniques opens the possibility to perform fast screening of structure–property relationships in complex materials. PMID:23471140

  1. Numerical Analysis of Residual Stress and Distortion Use Finite Element Method on Inner Bottom Construction of Geomarin IV Survey Ship with Welding Sequence Variations

    NASA Astrophysics Data System (ADS)

    Syahroni, N.; Hartono, A. B. W.; Murtedjo, M.

    2018-03-01

    In the ship fabrication industry, welding is the most critical stage. If the quality of welding on ship fabrication is not good, then it will affect the strength and overall appearance of the structure. One of the factors that affect the quality of welding is residual stress and distortion. In this research welding simulation is performed on the inner bottom construction of Geomarin IV Ship Survey using shell element and has variation to welding sequence. In this study, welding simulations produced peak temperatures at 2490 K at variation 4. While the lowest peak temperature was produced by variation 2 with a temperature of 2339 K. After welding simulation, it continued simulating residual stresses and distortion. The smallest maximum tensile residual stress found in the inner bottom construction is 375.23 MPa, and the maximum tensile pressure is -20.18 MPa. The residual stress is obtained from variation 3. The distortion occurring in the inner bottom construction for X=720 mm is 4.2 mm and for X=-720 mm, the distortion is 4.92 mm. The distortion is obtained from the variation 3. Near the welding area, distortion value reaches its minimum point. This is because the stiffeners in the form of frames serves as anchoring.

  2. Elastic/plastic analyses of advanced composites investigating the use of the compliant layer concept in reducing residual stresses resulting from processing

    NASA Technical Reports Server (NTRS)

    Arnold, Steven M.; Arya, Vinod K.; Melis, Matthew E.

    1990-01-01

    High residual stresses within intermetallic and metal matrix composite systems can develop upon cooling from the processing temperature to room temperature due to the coefficient of thermal expansion (CTE) mismatch between the fiber and matrix. As a result, within certain composite systems, radial, circumferential, and/or longitudinal cracks have been observed to form at the fiber-matrix interface. The compliant layer concept (insertion of a compensating interface material between the fiber and matrix) was proposed to reduce or eliminate the residual stress buildup during cooling and thus minimize cracking. The viability of the proposed compliant layer concept is investigated both elastically and elastoplastically. A detailed parametric study was conducted using a unit cell model consisting of three concentric cylinders to determine the required character (i.e., thickness and material properties) of the compliant layer as well as its applicability. The unknown compliant layer mechanical properties were expressed as ratios of the corresponding temperature dependent Ti-24Al-11Nb (a/o) matrix properties. The fiber properties taken were those corresponding to SCS-6 (SiC). Results indicate that the compliant layer can be used to reduce, if not eliminate, radial and circumferential residual stresses within the fiber and matrix and therefore also reduce or eliminate the radial cracking. However, with this decrease in in-plane stresses, one obtains an increase in longitudinal stress, thus potentially initiating longitudinal cracking. Guidelines are given for the selection of a specific compliant material, given a perfectly bonded system.

  3. Three-dimensional local residual stress and orientation gradients near graphite nodules in ductile cast iron [3D local residual stress and orientation gradients near graphite nodules in ductile cast iron

    DOE PAGES

    Zhang, Y. B.; Andriollo, T.; Faester, S.; ...

    2016-09-14

    A synchrotron technique, differential aperture X-ray microscopy (DAXM), has been applied to characterize the microstructure and analyze the local mesoscale residual elastic strain fields around graphite nodules embedded in ferrite matrix grains in ductile cast iron. Compressive residual elastic strains are measured with a maximum strain of ~6.5–8 × 10 –4 near the graphite nodules extending into the matrix about 20 μm, where the elastic strain is near zero. The experimental data are compared with a strain gradient calculated by a finite element model, and good accord has been found but with a significant overprediction of the maximum strain. Thismore » is discussed in terms of stress relaxation during cooling or during storage by plastic deformation of the nodule, the matrix or both. Furthermore, relaxation by plastic deformation of the ferrite is demonstrated by the formation of low energy dislocation cell structure also quantified by the DAXM technique.« less

  4. Analyses of Failure Mechanisms and Residual Stresses in Graphite/Polyimide Composites Subjected to Shear Dominated Biaxial Loads

    NASA Technical Reports Server (NTRS)

    Kumosa, M.; Predecki, P. K.; Armentrout, D.; Benedikt, B.; Rupnowski, P.; Gentz, M.; Kumosa, L.; Sutter, J. K.

    2002-01-01

    This research contributes to the understanding of macro- and micro-failure mechanisms in woven fabric polyimide matrix composites based on medium and high modulus graphite fibers tested under biaxial, shear dominated stress conditions over a temperature range of -50 C to 315 C. The goal of this research is also to provide a testing methodology for determining residual stress distributions in unidirectional, cross/ply and fabric graphite/polyimide composites using the concept of embedded metallic inclusions and X-ray diffraction (XRD) measurements.

  5. 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.

  6. Residual stress and bending strength of ZnO films deposited on polyimide sheet by RF sputtering system

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kusaka, Kazuya, E-mail: kusaka@tokushima-u.ac.jp; Maruoka, Yutaka, E-mail: ymaruoka1116@gmail.com; Matsue, Tatsuya, E-mail: tmatsue@mat.niihama-nct.ac.jp

    2016-05-15

    Zinc oxide (ZnO) films were deposited on a soft polyimide sheet substrate by radio frequency sputtering with a ZnO powder target, and the films' crystal orientations and residual stress were investigated using x-ray diffraction as a function of substrate temperature. C-axis oriented ZnO films were achieved using this ZnO powder target method. The ZnO films exhibited high compressive residual stresses between −0.7 and −1.4 GPa. Finally, the authors examined the strength of the obtained film by applying tensile bending loads. No cracks were observed on the surfaces of the ZnO films after a bending test using cylinders with diameters >25 mm. Aftermore » a bending test using a cylinder with a diameter of 19 mm, large cracks were formed on the films. Therefore, the authors concluded that the tensile bending strength of the obtained films was greater than ∼420 MPa.« less

  7. FE-simulation of hot forging with an integrated heat treatment with the objective of residual stress prediction

    NASA Astrophysics Data System (ADS)

    Behrens, Bernd-Arno; Chugreeva, Anna; Chugreev, Alexander

    2018-05-01

    Hot forming as a coupled thermo-mechanical process comprises numerous material phenomena with a corresponding impact on the material behavior during and after the forming process as well as on the final component performance. In this context, a realistic FE-simulation requires reliable mathematical models as well as detailed thermo-mechanical material data. This paper presents experimental and numerical results focused on the FE-based simulation of a hot forging process with a subsequent heat treatment step aiming at the prediction of the final mechanical properties and residual stress state in the forged component made of low alloy CrMo-steel DIN 42CrMo4. For this purpose, hot forging experiments of connecting rod geometry with a corresponding metallographic analysis and x-ray residual stress measurements have been carried out. For the coupled thermo-mechanical-metallurgical FE-simulations, a special user-defined material model based on the additive strain decomposition method and implemented in Simufact Forming via MSC.Marc solver features has been used.

  8. Retirement and drinking outcomes: lingering effects of workplace stress?

    PubMed

    Richman, Judith A; Zlatoper, Kenneth W; Zackula Ehmke, Jennifer L; Rospenda, Kathleen M

    2006-05-01

    This study assesses the degree to which sexual harassment (SH), generalized workplace abuse (GWA), and psychological workload (PWL) impact drinking behaviors in retirement. A mail survey was completed at four points in time by a cohort of 1654 employees initially drawn from a university workplace. Questionnaires assessed experiences of SH, GWA, PWL and drinking behaviors. Hypotheses were tested involving (1) the extent to which SH, GWA, and PWL experienced while working were associated with frequency and quantity of drinking in retirement, (2) the extent to which drinking levels of retirees differed from those of current employees experiencing similar stress levels, and (3) the extent to which gender moderated these relationships. Retirees reporting earlier stressful work environments report higher levels of alcohol consumption during retirement compared to those retirees reporting less stressful earlier work environments. Gender moderated these relationships. The findings of this study suggest that there may be a residual effect of workplace stress during retirement.

  9. Yield strength mapping in the cross section of ERW pipes considering kinematic hardening and residual stress

    NASA Astrophysics Data System (ADS)

    Kim, Dongwook; Quagliato, Luca; Lee, Wontaek; Kim, Naksoo

    2017-09-01

    In the ERW (electric resistance welding) pipe manufacturing, material properties, process conditions and settings strongly influences the mechanical performances of the final product, as well as they can make them to be not uniform and to change from point to point in the pipe. The present research work proposes an integrated numerical model for the study of the whole ERW process, considering roll forming, welding and sizing stations, allowing to infer the influence of the process parameters on the final quality of the pipe, in terms of final shape and residual stress. The developed numerical model has been initially validated comparing the dimensions of the pipe derived from the simulation results with those of industrial production, proving the reliability of the approach. Afterwards, by varying the process parameters in the numerical simulation, namely the roll speed, the sizing ratio and the friction factor, the influence on the residual stress in the pipe, at the end of the process and after each station, is studied and discussed along the paper.

  10. Investigation on the Residual Stress State of Drawn Tubes by Numerical Simulation and Neutron Diffraction Analysis

    PubMed Central

    Palkowski, Heinz; Brück, Sebastian; Pirling, Thilo; Carradò, Adele

    2013-01-01

    Cold drawing is widely applied in the industrial production of seamless tubes, employed for various mechanical applications. During pre-processing, deviations in tools and their adjustment lead to inhomogeneities in the geometry of the tubes and cause a gradient in residuals. In this paper a three dimensional finite element (3D-FE)-model is presented which was developed to calculate the change in wall thickness, eccentricity, ovality and residual macro-stress state of the tubes, produced by cold drawing. The model simulates the drawing process of tubes, drawn with and without a plug. For finite element modelling, the commercial software package Abaqus was used. To validate the model, neutron strain imaging measurements were performed on the strain imaging instrument SALSA at the Institute Laue Langevin (ILL, Grenoble, France) on a series of SF-copper tubes, drawn under controlled laboratory conditions, varying the drawing angle and the plug geometry. It can be stated that there is sufficient agreement between the finite element method (FEM)-calculation and the neutron stress determination. PMID:28788380

  11. Inversion of residual stress profiles from ultrasonic Rayleigh wave dispersion data

    NASA Astrophysics Data System (ADS)

    Mora, P.; Spies, M.

    2018-05-01

    We investigate theoretically and with synthetic data the performance of several inversion methods to infer a residual stress state from ultrasonic surface wave dispersion data. We show that this particular problem may reveal in relevant materials undesired behaviors for some methods that could be reliably applied to infer other properties. We focus on two methods, one based on a Taylor-expansion, and another one based on a piecewise linear expansion regularized by a singular value decomposition. We explain the instabilities of the Taylor-based method by highlighting singularities in the series of coefficients. At the same time, we show that the other method can successfully provide performances which only weakly depend on the material.

  12. Residual stresses in high temperature corrosion of pure zirconium using elasto-viscoplastic model: Application to the deflection test in monofacial oxidation

    NASA Astrophysics Data System (ADS)

    Fettré, D.; Bouvier, S.; Favergeon, J.; Kurpaska, L.

    2015-12-01

    The paper is devoted to modeling residual stresses and strains in an oxide film formed during high temperature oxidation. It describes the deflection test in isothermal high-temperature monofacial oxidation (DTMO) of pure zirconium. The model incorporates kinetics and mechanism of oxidation and takes into account elastic, viscoplastic, growth and chemical strains. Different growth strains models are considered, namely, isotropic growth strains given by Pilling-Bedworth ratio, anisotropic growth strains defined by Parise and co-authors and physically based model for growth strain proposed by Clarke. Creep mechanisms based on dislocation slip and core diffusion, are used. A mechanism responsible for through thickness normal stress gradient in the oxide film is proposed. The material parameters are identified using deflection tests under 400 °C, 500 °C and 600 °C. The effect of temperature on creep and stress relaxation is analyzed. Numerical sensitivity study of the DTMO experiment is proposed in order to investigate the effects of the initial foil thickness and platinum coating on the deflection curves.

  13. Modeling of process-induced residual stresses and resin flow behavior in resin transfer molded composites with woven fiber mats

    NASA Astrophysics Data System (ADS)

    Golestanian, Hossein

    This research focuses on modeling Resin Transfer Molding process for manufacture of composite parts with woven fiber mats. Models are developed to determine cure dependent stiffness matrices for composites manufactured with two types of woven fiber mats. Five-harness carbon and eight-harness fiberglass mats with EPON 826 resin composites are considered. The models presented here take into account important material/process parameters with emphasis on; (1) The effects of cure-dependent resin mechanical properties, (2) Fiber undulation due to the weave of the fiber fill and warp bundles, and (3) Resin interaction with the fiber bundles at a microscopic scale. Cure-dependent mechanical properties were then used in numerical models to determine residual stresses and deformation in the composite parts. The complete cure cycle was modeled in these analyses. Also the cool down stage after the composite cure was analyzed. The effect of 5% resin shrinkage on residual stresses and deformations was also investigated. In the second part of the study, Finite Element models were developed to simulate mold filling in RTM processes. Resin flow in the fiber mats was modeled as flow through porous media. Physical models were also developed to investigate resin flow behavior into molds of rectangular and irregular shapes. Silicone fluids of 50 and 100 centistoke viscosities as well as EPON 826 epoxy resin were used in the mold filling experiments. The reinforcements consisted of several layers of woven fiberglass and carbon fiber mats. The effects of injection pressure, fluid viscosity, type of reinforcement, and mold geometry on mold filling times were investigated. Fiber mat permeabilities were determined experimentally for both types of reinforcements. Comparison of experimental and numerical resin front positions indicated the importance of edge effects in resin flow behavior in small cavities. The resin front positions agreed well for the rectangular mold geometry.

  14. Determination of residual stress in a microtextured α titanium component using high-energy synchrotron X-rays

    DOE PAGES

    Park, Jun -Sang; Ray, Atish K.; Dawson, Paul R.; ...

    2016-05-02

    A shrink-fit sample is manufactured with a Ti-8Al-1Mo-1V alloy to introduce a multiaxial residual stress field in the disk of the sample. A set of strain and orientation pole figures are measured at various locations across the disk using synchrotron high-energy X-ray diffraction. Two approaches—the traditional sin 2Ψ method and the bi-scale optimization method—are taken to determine the stresses in the disk based on the measured strain and orientation pole figures, to explore the range of solutions that are possible for the stress field within the disk. While the stress components computed using the sin 2Ψ method and the bi-scalemore » optimization method have similar trends, their magnitudes are significantly different. Lastly, it is suspected that the local texture variation in the material is the cause of this discrepancy.« less

  15. Research and Development Program to Develop a Nondestructive Evaluation Instrument (X-Ray Diffraction) for Measuring Residual Stresses in a Wide Range of Naval Aviation Material. Phase 2

    DTIC Science & Technology

    1987-04-03

    Using Cr KO Radiation 3-20 Smaary of Residual Stress for Navy Pensacola Nickel-Plated 3-64 Camshaft 75 £51 3-21 Surface Residual Stresses in Nickel-Plated...NAN - Pensacola. The data obtained from the H-3 camshafts produced perplexing results due to sLn 2 * splitting and non-linear d-spacing versus sin2...com- pressive stress values on one of the nickel-plated camshafts . An additional objective of the Phase II nickel-plating study was to under- stand the

  16. 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.

  17. Implementation and Development of the Incremental Hole Drilling Method for the Measurement of Residual Stress in Thermal Spray Coatings

    NASA Astrophysics Data System (ADS)

    Valente, T.; Bartuli, C.; Sebastiani, M.; Loreto, A.

    2005-12-01

    The experimental measurement of residual stresses originating within thick coatings deposited by thermal spray on solid substrates plays a role of fundamental relevance in the preliminary stages of coating design and process parameters optimization. The hole-drilling method is a versatile and widely used technique for the experimental determination of residual stress in the most superficial layers of a solid body. The consolidated procedure, however, can only be implemented for metallic bulk materials or for homogeneous, linear elastic, and isotropic materials. The main objective of the present investigation was to adapt the experimental method to the measurement of stress fields built up in ceramic coatings/metallic bonding layers structures manufactured by plasma spray deposition. A finite element calculation procedure was implemented to identify the calibration coefficients necessary to take into account the elastic modulus discontinuities that characterize the layered structure through its thickness. Experimental adjustments were then proposed to overcome problems related to the low thermal conductivity of the coatings. The number of calculation steps and experimental drilling steps were finally optimized.

  18. The Effect of Tungsten and Niobium on the Stress Relaxation Rates of Disk Alloy CH98

    NASA Technical Reports Server (NTRS)

    Gayda, John

    2003-01-01

    Gas turbine engines for future subsonic transports will probably have higher pressure ratios which will require nickel-base superalloy disks with 1300 to 1400 F temperature capability. Several advanced disk alloys are being developed to fill this need. One of these, CH98, is a promising candidate for gas turbine engines and is being studied in NASA s Advanced Subsonic Technology (AST) program. For large disks, residual stresses generated during quenching from solution heat treatment are often reduced by a stabilization heat treatment, in which the disk is heated to 1500 to 1600 F for several hours followed by a static air cool. The reduction in residual stress levels lessens distortion during machining of disks. However, previous work on CH98 has indicated that stabilization treatments decrease creep capability. Additions of the refractory elements tungsten and niobium improve tensile and creep properties after stabilization, while maintaining good crack growth resistance at elevated temperatures. As the additions of refractory elements increase creep capability, they might also effect stress relaxation rates and therefore the reduction in residual stress levels obtained for a given stabilization treatment. To answer this question, the stress relaxation rates of CH98 with and without tungsten and niobium additions are compared in this paper for temperatures and times generally employed in stabilization treatments on modern disk alloys.

  19. 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.

  20. The 14 month wind stressed residual circulation (pole tide) in the North Sea

    NASA Technical Reports Server (NTRS)

    Oconnor, W. P.

    1986-01-01

    From published research it is known that a quasi-periodic 14 month atmospheric pressure oscillation of a few tenths of a millibar exists in the region of the North and Baltic Seas. At some time in the cycle the associated wind stress has a westerly component that drives a circulation in the North Sea. The results of a dynamical model and comparisons with several North Sea residual circulation studies show that a large sea level gradient results along the Dutch coast. It is this feature that has been referred to as the enhanced pole tide. The dynamical similarity of this pole tide in the North and Baltic Seas to the annual and seasonal wind forced circulations is considered. It is inferred that the large deviations of the pole tide from equilibrium at coastal stations are the result of this sea level set up forces by the 14 month wind stress cycle.

  1. Kinetic model for thin film stress including the effect of grain growth

    NASA Astrophysics Data System (ADS)

    Chason, Eric; Engwall, A. M.; Rao, Z.; Nishimura, T.

    2018-05-01

    Residual stress during thin film deposition is affected by the evolution of the microstructure. This can occur because subsurface grain growth directly induces stress in the film and because changing the grain size at the surface affects the stress in new layers as they are deposited. We describe a new model for stress evolution that includes both of these effects. It is used to explain stress in films that grow with extensive grain growth (referred to as zone II) so that the grain size changes throughout the thickness of the layer as the film grows. Equations are derived for different cases of high or low atomic mobility where different assumptions are used to describe the diffusion of atoms that are incorporated into the grain boundary. The model is applied to measurements of stress and grain growth in evaporated Ni films. A single set of model parameters is able to explain stress evolution in films grown at multiple temperatures and growth rates. The model explains why the slope of the curvature measurements changes continuously with thickness and attributes it to the effect of grain size on new layers deposited on the film.

  2. Residual effects of combat-related mild traumatic brain injury.

    PubMed

    Kontos, Anthony P; Kotwal, Russ S; Elbin, R J; Lutz, Robert H; Forsten, Robert D; Benson, Peter J; Guskiewicz, Kevin M

    2013-04-15

    Mild traumatic brain injury (mTBI) has gained considerable notoriety during the past decade of conflict in Afghanistan and Iraq. However, the relationship between combat-related mTBI and residual mTBI symptoms, post-traumatic stress disorder (PTSD) symptoms, and neurocognitive deficits remains unclear. The purpose of the study was to compare residual mTBI and PTSD symptoms, and neurocognitive deficits among U.S. Army Special Operations Command (USASOC) personnel with diagnosed blunt, blast, and blast-blunt combination mTBIs. This study involved a retrospective medical records review of 27,169 USASOC personnel who completed a military version of the Immediate Post-Concussion Assessment Cognitive Test (ImPACT), Post-Concussion Symptom Scale (PCSS), and PTSD Checklist (PCL) between November 2009 and December 2011. Of the 22,203 personnel who met criteria for the study, 2,813 (12.7%) had a diagnosis of at least one mTBI. A total of 28% (n=410) of USASOC personnel with a history of diagnosed mTBI reported clinical levels of PTSD symptoms. Personnel with a history of diagnosed blunt (OR=3.58), blast (OR=4.23) or combination (OR=5.73) mTBI were at significantly (p=0.001) greater risk of reporting clinical levels of PTSD symptoms than those with no history of mTBI. A dose-response gradient for exposure to blast/combination mTBI on clinical levels of PTSD symptoms was also significant (p=0.001). Individuals with blast/combination mTBIs scored higher in residual mTBI (p=0.001) and PTSD symptoms (p=0.001), and performed worse on tests of visual memory (p=0.001), and reaction time (p=0.001) than those with blunt or no mTBI history. Individuals with combination mTBIs scored lower in verbal memory (p=0.02) than those with blunt mTBIs. Residual PTSD and mTBI symptoms appear to be more prevalent in personnel with blast mTBI. A dose-response gradient for blast mTBI and symptoms suggests that repeated exposures to these injuries may have lingering effects.

  3. Residual Stress and Fracture of PECVD Thick Oxide Films for Power MEMS Structures and Devices

    DTIC Science & Technology

    2007-06-01

    Residual stress leads to large overall wafer bow, which makes further processing difficult. For example some microfabrication machines , such as chemical...curvature will be measured across the wafer surface in 12 scans, rotating 24 the wafer by 300 between each scan. In situ wafer curvature will be...SiOx. 4.1. Introduction As introduced earlier (Sec.1), in Power MEMS (micro energy- harvesting devices such as micro heat engines and related components

  4. Residual stress determination in oxide layers at different length scales combining Raman spectroscopy and X-ray diffraction: Application to chromia-forming metallic alloys

    DOE PAGES

    Guerain, Mathieu; Grosseau-Poussard, Jean-Luc; Geandier, Guillaume; ...

    2017-11-21

    In oxidizing environments, the protection of metals and alloys against further oxidation at high temperature is provided by the oxide film itself. This protection is efficient only if the formed film adheres well to the metal (substrate), i.e., without microcracks and spalls induced by thermomechanical stresses. In this study, the residual stresses at both macroscopic and microscopic scales in the oxide film adhering to the substrate and over the damaged areas have been rigorously determined on the same samples for both techniques. Ni-30Cr and Fe-47Cr alloys have been oxidized together at 900 and 1000 °C, respectively, to create films withmore » a thickness of a few microns. A multi-scale approach was adopted: macroscopic stress was determined by conventional X-ray diffraction and Raman spectroscopy, while microscopic residual stress mappings were performed over different types of bucklings using Raman micro-spectroscopy and synchrotron micro-diffraction. A very good agreement is found at macro- and microscales between the residual stress values obtained with both techniques, giving confidence on the reliability of the measurements. In addition, relevant structural information at the interface between the metallic substrate and the oxide layer was collected by micro-diffraction, a non-destructive technique that allows mapping through the oxide layer, and both the grain size and the crystallographic orientation of the supporting polycrystalline metal located either under a buckling or not were measured.« less

  5. Residual stress determination in oxide layers at different length scales combining Raman spectroscopy and X-ray diffraction: Application to chromia-forming metallic alloys

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Guerain, Mathieu; Grosseau-Poussard, Jean-Luc; Geandier, Guillaume

    In oxidizing environments, the protection of metals and alloys against further oxidation at high temperature is provided by the oxide film itself. This protection is efficient only if the formed film adheres well to the metal (substrate), i.e., without microcracks and spalls induced by thermomechanical stresses. In this study, the residual stresses at both macroscopic and microscopic scales in the oxide film adhering to the substrate and over the damaged areas have been rigorously determined on the same samples for both techniques. Ni-30Cr and Fe-47Cr alloys have been oxidized together at 900 and 1000 °C, respectively, to create films withmore » a thickness of a few microns. A multi-scale approach was adopted: macroscopic stress was determined by conventional X-ray diffraction and Raman spectroscopy, while microscopic residual stress mappings were performed over different types of bucklings using Raman micro-spectroscopy and synchrotron micro-diffraction. A very good agreement is found at macro- and microscales between the residual stress values obtained with both techniques, giving confidence on the reliability of the measurements. In addition, relevant structural information at the interface between the metallic substrate and the oxide layer was collected by micro-diffraction, a non-destructive technique that allows mapping through the oxide layer, and both the grain size and the crystallographic orientation of the supporting polycrystalline metal located either under a buckling or not were measured.« less

  6. Residual stress determination in oxide layers at different length scales combining Raman spectroscopy and X-ray diffraction: Application to chromia-forming metallic alloys

    NASA Astrophysics Data System (ADS)

    Guerain, Mathieu; Grosseau-Poussard, Jean-Luc; Geandier, Guillaume; Panicaud, Benoit; Tamura, Nobumichi; Kunz, Martin; Dejoie, Catherine; Micha, Jean-Sebastien; Thiaudière, Dominique; Goudeau, Philippe

    2017-11-01

    In oxidizing environments, the protection of metals and alloys against further oxidation at high temperature is provided by the oxide film itself. This protection is efficient only if the formed film adheres well to the metal (substrate), i.e., without microcracks and spalls induced by thermomechanical stresses. In this study, the residual stresses at both macroscopic and microscopic scales in the oxide film adhering to the substrate and over the damaged areas have been rigorously determined on the same samples for both techniques. Ni-30Cr and Fe-47Cr alloys have been oxidized together at 900 and 1000 °C, respectively, to create films with a thickness of a few microns. A multi-scale approach was adopted: macroscopic stress was determined by conventional X-ray diffraction and Raman spectroscopy, while microscopic residual stress mappings were performed over different types of bucklings using Raman micro-spectroscopy and synchrotron micro-diffraction. A very good agreement is found at macro- and microscales between the residual stress values obtained with both techniques, giving confidence on the reliability of the measurements. In addition, relevant structural information at the interface between the metallic substrate and the oxide layer was collected by micro-diffraction, a non-destructive technique that allows mapping through the oxide layer, and both the grain size and the crystallographic orientation of the supporting polycrystalline metal located either under a buckling or not were measured.

  7. Determination of Pesticides Residues in Cucumbers Grown in Greenhouse and the Effect of Some Procedures on Their Residues.

    PubMed

    Leili, Mostafa; Pirmoghani, Amin; Samadi, Mohammad Taghi; Shokoohi, Reza; Roshanaei, Ghodratollah; Poormohammadi, Ali

    2016-11-01

    The objective of this study was to determine the residual concentrations of ethion and imidacloprid in cucumbers grown in greenhouse. The effect of some simple processing procedures on both ethion and imidacloprid residues were also studied. Ten active greenhouses that produce cucumber were randomly selected. Ethion and imidacloprid as the most widely used pesticides were measured in cucumber samples of studied greenhouses. Moreover, the effect of storing, washing, and peeling as simple processing procedures on both ethion and imidacloprid residues were investigated. One hour after pesticide application; the maximum residue levels (MRLs) of ethion and imidacloprid were higher than that of Codex standard level. One day after pesticide application, the levels of pesticides were decreased about 35 and 31% for ethion and imidacloprid, respectively, which still were higher than the MRL. Washing procedure led to about 51 and 42.5% loss in ethion and imidacloprid residues, respectively. Peeling procedure also led to highest loss of 93.4 and 63.7% in ethion and imidacloprid residues, respectively. The recovery for both target analytes was in the range between 88 and 102%. The residue values in collected samples one hour after pesticides application were higher than standard value. The storing, washing, and peeling procedures lead to the decrease of pesticide residues in greenhouse cucumbers. Among them, the peeling procedure has the greatest impact on residual reduction. Therefore, these procedures can be used as simple and effective processing techniques for reducing and removing pesticides from greenhouse products before their consumption.

  8. Residual stresses and phase transformations in Ytterbium silicate environmental barrier coatings

    NASA Astrophysics Data System (ADS)

    Stolzenburg, Fabian

    Due to their high melting temperature, low density, and good thermomechanical stability, silicon-based ceramics (SiC, Si3N4) are some of the most promising materials systems for high temperature structural applications in gas turbine engines. However, their silica surface layer reacts with water vapor contained in combustion environments. The resulting hydroxide layer volatilizes, leading to component recession. Environmental barrier coatings (EBCs) have been developed to shield the substrate from degradation. Next generation coatings for silicon-based ceramics based on ytterbium silicates have shown a promising combination of very low and good thermomechanical properties. The focus of this thesis is threefold: In the first part, phase transformations in plasma sprayed ytterbium silicates were investigated. Plasma sprayed materials are known to contain large amounts of amorphous material. Phase changes during the conversion from amorphous to crystalline materials were investigated as they have been known to lead to failure in many coatings. The second part of this work focused on measuring residual stresses in multilayer EBCs using synchrotron X-ray diffraction (XRD). Strains were resolved spatially, with probe sizes as small as 20 um. Stresses were calculated using mechanical properties of ytterbium silicates, determined with in-situ loading and heating experiments. In-situ and ex-situ heating experiments allowed for the study of changes in stress states that occur in these EBC materials during heating and cooling cycles. Lastly, the interaction of ytterbium silicates with low-melting environmental calcium-magnesium-aluminosilicate (CMAS) glasses was studied. Synchrotron XRD was used to study the influence of CMAS on the stress state in the coating, X-ray computed tomography was used to provide 3D images of coatings, and EDS and TEM analysis were used to study the interactions at the CMAS/ytterbium silicate interface in detail.

  9. Essential features of residual stress determination in thin-walled plane structures in a base of whole field interferometric measurements

    NASA Astrophysics Data System (ADS)

    Pisarev, Vladimir S.; Odintsev, I.; Balalov, V.; Apalkov, A.

    2003-05-01

    Sophisticated technique for reliable quantitative deriving residual stress values from initial experimental data, which are inherent in combined implementing the hole drilling method with both holographic and speckle interferometry, is described in detail. The approach developed includes both possible ways of obtaining initial experimental information. The first of them consists of recording a set of required interference fringe patterns, which are resulted from residual stress energy release after through hole drilling, in two orthogonal directions that coincide with principal strain directions. The second way is obtaining a series of interrelated fringe patterns when a direction of either observation in reflection hologram interferometry or dual-beam illumination in speckle interferometry lies arbitrary with respect to definite principal strain direction. A set of the most typical both actual and analogous reference fringe patterns, which are related to both reflection hologram and dual-beam speckle interferometry, are presented.

  10. Investigating the effect of the high power and high speed CO2 laser surface melting on the residual stresses and corrosion resistance of 316L stainless steel

    NASA Astrophysics Data System (ADS)

    Obeidi, Muhannad A.; McCarthy, Eanna; Brabazon, Dermot

    2018-05-01

    This study is investigating the effect of the laser surface melting of 316L stainless steel cylindrical samples on the surface residual stresses and the corrosion resistance. A high speed CO2 laser beam with power range of 300-500 W was used in pulse mode to initiate the surface melting in an argon and argon-nitrogen atmosphere. The produced samples were cross sectioned and the elastic modulus and nano-hardness test were carried out showing no alteration between the modified and the bulk material. A noticeable degradation in the corrosion resistance was found due to the formation of the chromium carbide and chromium nitride which act as electrolytic cells in addition to the disruption of the free chromium content at the melted zone.

  11. Multiscale Analysis of the Residual Stresses Occurring During Curing and Cooling of Thick-Wall Cross-Ply Filament-Wound Cylinders

    NASA Astrophysics Data System (ADS)

    Memarianfard, H.; Turusov, R. A.

    2017-11-01

    A nonlinear numerical multiscale analysis to predict the residual shrinkage and thermal stresses arising during curing and cooling of thickwall cross-ply filament-wound cylinders of a reinforced polymer is performed at macro- and microscales using the representative volume element (RVE) of the composite. The mechanical behavior of the polymeric matrix is described by a nonlinear viscoelastic model with account of chemical shrinkage. The fiber material is considered elastic, isotropic, and temperature-independent. The maximum residual macrostresses arising during manufacture of the cylinders were calculated. The fields of residual microstresses in the RVE in three different zones across the thickness of the cylinders were found. Results of the microscale analysis showed that microstresses in some zones of RVE were several times higher than macrostresses in these areas.

  12. Viscoelastic Thin Polymer Films under Transient Residual Stresses: Two-Stage Dewetting on Soft Substrates

    NASA Astrophysics Data System (ADS)

    Al Akhrass, S.; Reiter, G.; Hou, S. Y.; Yang, M. H.; Chang, Y. L.; Chang, F. C.; Wang, C. F.; Yang, A. C.-M.

    2008-05-01

    A nonmonotonic, two-stage dewetting behavior was observed for spin coated thin viscoelastic polymer films on soft elastic substrates. At times shorter than the relaxation time of the polymer (t<τrep), dewetting generated deep trenches in the soft rubbery substrate which, in turn, almost stopped dewetting. At later stages (t≫τrep), dewetting accelerated, accompanied by an unstable rim. However, holes nucleated at t<τrep showed only this second-stage behavior. Our observations are attributed to large elastic deformations in the substrate caused by transient residual stresses within the film.

  13. Monitoring Pre-Stressed Composites Using Optical Fibre Sensors.

    PubMed

    Krishnamurthy, Sriram; Badcock, Rodney A; Machavaram, Venkata R; Fernando, Gerard F

    2016-05-28

    Residual stresses in fibre reinforced composites can give rise to a number of undesired effects such as loss of dimensional stability and premature fracture. Hence, there is significant merit in developing processing techniques to mitigate the development of residual stresses. However, tracking and quantifying the development of these fabrication-induced stresses in real-time using conventional non-destructive techniques is not straightforward. This article reports on the design and evaluation of a technique for manufacturing pre-stressed composite panels from unidirectional E-glass/epoxy prepregs. Here, the magnitude of the applied pre-stress was monitored using an integrated load-cell. The pre-stressing rig was based on a flat-bed design which enabled autoclave-based processing. A method was developed to end-tab the laminated prepregs prior to pre-stressing. The development of process-induced residual strain was monitored in-situ using embedded optical fibre sensors. Surface-mounted electrical resistance strain gauges were used to measure the strain when the composite was unloaded from the pre-stressing rig at room temperature. Four pre-stress levels were applied prior to processing the laminated preforms in an autoclave. The results showed that the application of a pre-stress of 108 MPa to a unidirectional [0]16 E-glass/913 epoxy preform, reduced the residual strain in the composite from -600 µε (conventional processing without pre-stress) to approximately zero. A good correlation was observed between the data obtained from the surface-mounted electrical resistance strain gauge and the embedded optical fibre sensors. In addition to "neutralising" the residual stresses, superior axial orientation of the reinforcement can be obtained from pre-stressed composites. A subsequent publication will highlight the consequences of pres-stressing on fibre alignment, the tensile, flexural, compressive and fatigue performance of unidirectional E-glass composites.

  14. Monitoring Pre-Stressed Composites Using Optical Fibre Sensors

    PubMed Central

    Krishnamurthy, Sriram; Badcock, Rodney A.; Machavaram, Venkata R.; Fernando, Gerard F.

    2016-01-01

    Residual stresses in fibre reinforced composites can give rise to a number of undesired effects such as loss of dimensional stability and premature fracture. Hence, there is significant merit in developing processing techniques to mitigate the development of residual stresses. However, tracking and quantifying the development of these fabrication-induced stresses in real-time using conventional non-destructive techniques is not straightforward. This article reports on the design and evaluation of a technique for manufacturing pre-stressed composite panels from unidirectional E-glass/epoxy prepregs. Here, the magnitude of the applied pre-stress was monitored using an integrated load-cell. The pre-stressing rig was based on a flat-bed design which enabled autoclave-based processing. A method was developed to end-tab the laminated prepregs prior to pre-stressing. The development of process-induced residual strain was monitored in-situ using embedded optical fibre sensors. Surface-mounted electrical resistance strain gauges were used to measure the strain when the composite was unloaded from the pre-stressing rig at room temperature. Four pre-stress levels were applied prior to processing the laminated preforms in an autoclave. The results showed that the application of a pre-stress of 108 MPa to a unidirectional [0]16 E-glass/913 epoxy preform, reduced the residual strain in the composite from −600 µε (conventional processing without pre-stress) to approximately zero. A good correlation was observed between the data obtained from the surface-mounted electrical resistance strain gauge and the embedded optical fibre sensors. In addition to “neutralising” the residual stresses, superior axial orientation of the reinforcement can be obtained from pre-stressed composites. A subsequent publication will highlight the consequences of pres-stressing on fibre alignment, the tensile, flexural, compressive and fatigue performance of unidirectional E-glass composites. PMID

  15. Magnetoelastic Effect-Based Transmissive Stress Detection for Steel Strips: Theory and Experiment

    PubMed Central

    Zhang, Qingdong; Su, Yuanxiao; Zhang, Liyuan; Bi, Jia; Luo, Jiang

    2016-01-01

    For the deficiencies of traditional stress detection methods for steel strips in industrial production, this paper proposes a non-contact stress detection scheme based on the magnetoelastic effect. The theoretical model of the transmission-type stress detection is established, in which the output voltage and the tested stress obey a linear relation. Then, a stress detection device is built for the experiment, and Q235 steel under uniaxial tension is tested as an example. The result shows that the output voltage rises linearly with the increase of the tensile stress, consistent with the theoretical prediction. To ensure the accuracy of the stress detection method in actual application, the temperature compensation, magnetic shielding and some other key technologies are investigated to reduce the interference of the external factors, such as environment temperature and surrounding magnetic field. The present research develops the theoretical and experimental foundations for the magnetic stress detection system, which can be used for online non-contact monitoring of strip flatness-related stress (tension distribution or longitudinal residual stress) in the steel strip rolling process, the quality evaluation of strip flatness after rolling, the life and safety assessment of metal construction and other industrial production links. PMID:27589742

  16. Uncovering the local inelastic interactions during manufacture of ductile cast iron: How the substructure of the graphite particles can induce residual stress concentrations in the matrix

    NASA Astrophysics Data System (ADS)

    Andriollo, Tito; Hellström, Kristina; Sonne, Mads Rostgaard; Thorborg, Jesper; Tiedje, Niels; Hattel, Jesper

    2018-02-01

    Recent X-ray diffraction (XRD) measurements have revealed that plastic deformation and a residual elastic strain field can be present around the graphite particles in ductile cast iron after manufacturing, probably due to some local mismatch in thermal contraction. However, as only one component of the elastic strain tensor could be obtained from the XRD data, the shape and magnitude of the associated residual stress field have remained unknown. To compensate for this and to provide theoretical insight into this unexplored topic, a combined experimental-numerical approach is presented in this paper. First, a material equivalent to the ductile cast iron matrix is manufactured and subjected to dilatometric and high-temperature tensile tests. Subsequently, a two-scale hierarchical top-down model is devised, calibrated on the basis of the collected data and used to simulate the interaction between the graphite particles and the matrix during manufacturing of the industrial part considered in the XRD study. The model indicates that, besides the viscoplastic deformation of the matrix, the effect of the inelastic deformation of the graphite has to be considered to explain the magnitude of the XRD strain. Moreover, the model shows that the large elastic strain perturbations recorded with XRD close to the graphite-matrix interface are not artifacts due to e.g. sharp gradients in chemical composition, but correspond to residual stress concentrations induced by the conical sectors forming the internal structure of the graphite particles. In contrast to common belief, these results thus suggest that ductile cast iron parts cannot be considered, in general, as stress-free at the microstructural scale.

  17. A Comparison of Curing Process-Induced Residual Stresses and Cure Shrinkage in Micro-Scale Composite Structures with Different Constitutive Laws

    NASA Astrophysics Data System (ADS)

    Li, Dongna; Li, Xudong; Dai, Jianfeng; Xi, Shangbin

    2018-02-01

    In this paper, three kinds of constitutive laws, elastic, "cure hardening instantaneously linear elastic (CHILE)" and viscoelastic law, are used to predict curing process-induced residual stress for the thermoset polymer composites. A multi-physics coupling finite element analysis (FEA) model implementing the proposed three approaches is established in COMSOL Multiphysics-Version 4.3b. The evolution of thermo-physical properties with temperature and degree of cure (DOC), which improved the accuracy of numerical simulations, and cure shrinkage are taken into account for the three models. Subsequently, these three proposed constitutive models are implemented respectively in a 3D micro-scale composite laminate structure. Compared the differences between these three numerical results, it indicates that big error in residual stress and cure shrinkage generates by elastic model, but the results calculated by the modified CHILE model are in excellent agreement with those estimated by the viscoelastic model.

  18. Effect of aerobic fitness on the physiological stress responses at work.

    PubMed

    Ritvanen, Tiina; Louhevaara, Veikko; Helin, Pertti; Halonen, Toivo; Hänninen, Osmo

    2007-01-01

    The aim of the present study was to examine the effects of aerobic fitness on physiological stress responses experienced by teachers during working hours. Twenty-six healthy female and male teachers aged 33-62 years participated in the study. The ratings of perceived stress visual analogue scale (VAS), and the measurement of physiological responses (norepinephrine, epinephrine, cortisol, diastolic and systolic blood pressure, heart rate (HR), and trapezius muscle activity by electromyography (EMG), were determined. Predicted maximal oxygen uptake (VO(2)max) was measured using the submaximal bicycle ergometer test. The predicted VO(2)max was standardized for age using residuals of linear regression analyses. Static EMG activity, HR and VAS were associated with aerobic fitness in teachers. The results suggest that a higher level of aerobic fitness may reduce muscle tension, HR and perceived work stress in teachers.

  19. Influence of zirconia framework thickness on residual stress profile in veneering ceramic: measurement by hole-drilling.

    PubMed

    Mainjot, Amélie K; Schajer, Gary S; Vanheusden, Alain J; Sadoun, Michaël J

    2012-04-01

    Framework design is reported to influence chipping in zirconia-based restorations, which is an important cause of failure of such restorations. Residual stress profile in the veneering ceramic after the manufacturing process is an important predictive factor of the mechanical behavior of the material. The objective of this study is to investigate the influence of framework thickness on the stress profile measured in zirconia-based structures. The stress profile was measured with the hole-drilling method in bilayered disc samples of 20mm diameter with a 1.5 mm thick veneering ceramic layer. Six different framework thicknesses from 0.5 mm to 3 mm were studied. Two different cooling procedures were also investigated. Compressive stresses were observed in the surface, and tensile stresses in the depth of most of the samples. The slow cooling procedure was found to promote the development of interior tensile stresses, except for the sample with a 3mm thick framework. With the tempering procedure, samples with a 1.5 mm thick framework exhibited the most favorable stress profile, while thicker and thinner frameworks exhibited respectively in surface or interior tensile stresses. The measurements performed highlight the importance of framework thickness, which determine the nature of stresses and can explain clinical failures encountered, especially with thin frameworks. The adequate ratio between veneering ceramic and zirconia is hard to define, restricting the range of indications of zirconia-based restorations until a better understanding of such a delicate veneering process is achieved. Copyright © 2011 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

  20. Residual effects of hypnotics: an update.

    PubMed

    Hindmarch, I

    1991-07-01

    The sedative/hypnotic benzodiazepines introduced worldwide in the early 1960s were acclaimed for their low chemical toxicity and safety in clinical use. A decade later, some researchers and clinicians found that while all the drugs had undoubted potency and efficacy as sleep inducers and maintainers, the trade-off in residual effects (e.g., excessive daytime tiredness, poor concentration, impaired psychomotor performance, lowered mental abilities) was cause for concern. These sequelae not only affected patients' safety and ability to perform daytime tasks, but were also counter-therapeutic; the daytime sleep that was produced interfered with the natural nocturnal sleep. In a recent study, the degree to which patient abilities were impaired was measured by a number of psychomotor tests. Benzodiazepines with a duration of clinical effect of less than 8 to 10 hours produced fewer, less frequent residual effects than those with a measurable activity in excess of the normal nocturnal sleep period.

  1. Residual stress dependant anisotropic band gap of various (hkl) oriented BaI{sub 2} films

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Kumar, Pradeep; Gulia, Vikash; Vedeshwar, Agnikumar G., E-mail: agni@physics.du.ac.in, E-mail: agvedeshwar@gmail.com

    2013-11-21

    The thermally evaporated layer structured BaI{sub 2} grows in various completely preferred (hkl) film orientations with different growth parameters like film thickness, deposition rate, substrate temperature, etc. which were characterized by structural, morphological, and optical absorption measurements. Structural analysis reveals the strain in the films and the optical absorption shows a direct type band gap. The varying band gaps of these films were found to scale linearly with their strain. The elastic moduli and other constants were also calculated using Density Functional Theory (DFT) formalism implemented in WIEN2K code for converting the strain into residual stress. Films of different sixmore » (hkl) orientations show stress free anisotropic band gaps (2.48–3.43 eV) and both positive and negative pressure coefficients. The negative and positive pressure coefficients of band gap are attributed to the strain in I-I (or Ba-Ba or both) and Ba-I distances along [hkl], respectively. The calculated band gaps are also compared with those experimentally determined. The average pressure coefficient of band gap of all six orientations (−0.071 eV/GPa) found to be significantly higher than that calculated (−0.047 eV/GPa) by volumetric pressure dependence. Various these issues have been discussed with consistent arguments. The electron effective mass m{sub e}{sup *}=0.66m{sub 0} and the hole effective mass m{sub h}{sup *}=0.53m{sub 0} have been determined from the calculated band structure.« less

  2. Stress studies in EFG

    NASA Technical Reports Server (NTRS)

    1983-01-01

    A computer code which can account for plastic deformation effects on stress generated in silicon sheet grown at high speeds is fully operative. Stress and strain rate distributions are presented for two different sheet temperature profiles. The calculations show that residual stress levels are very sensitive to details of the cooling profile in a sheet with creep. Experimental work has been started in several areas to improve understanding of ribbon temperature profiles and stress distributions associated with a 10 cm wide ribbon cartridge system.

  3. Residual stress analysis on tensile MMC specimens after loading/unloading tests in several conditions

    NASA Astrophysics Data System (ADS)

    Giuliani, Alessandra; Albertini, Gianni; Manescu, Adrian

    2004-07-01

    Residual stresses have been investigated in samples made of AA6061+22% Al2O3 in order to correlate microstructural characteristics with mechanical performances. In particular, the possible occurrence of a brittle fracture induced by an excessive load transfer from the matrix to the reinforcement was investigated. To this end, macrostresses and microstresses were analysed. A neutron diffraction test on 12 specimens submitted to several loading/unloading conditions at different temperatures was performed. These measurements aimed to establish the optimal temperature for the initial extruded billet in pre-heating stage, before forging the final wheel hub.

  4. 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.

  5. Technical note: Equivalent genomic models with a residual polygenic effect.

    PubMed

    Liu, Z; Goddard, M E; Hayes, B J; Reinhardt, F; Reents, R

    2016-03-01

    Routine genomic evaluations in animal breeding are usually based on either a BLUP with genomic relationship matrix (GBLUP) or single nucleotide polymorphism (SNP) BLUP model. For a multi-step genomic evaluation, these 2 alternative genomic models were proven to give equivalent predictions for genomic reference animals. The model equivalence was verified also for young genotyped animals without phenotypes. Due to incomplete linkage disequilibrium of SNP markers to genes or causal mutations responsible for genetic inheritance of quantitative traits, SNP markers cannot explain all the genetic variance. A residual polygenic effect is normally fitted in the genomic model to account for the incomplete linkage disequilibrium. In this study, we start by showing the proof that the multi-step GBLUP and SNP BLUP models are equivalent for the reference animals, when they have a residual polygenic effect included. Second, the equivalence of both multi-step genomic models with a residual polygenic effect was also verified for young genotyped animals without phenotypes. Additionally, we derived formulas to convert genomic estimated breeding values of the GBLUP model to its components, direct genomic values and residual polygenic effect. Third, we made a proof that the equivalence of these 2 genomic models with a residual polygenic effect holds also for single-step genomic evaluation. Both the single-step GBLUP and SNP BLUP models lead to equal prediction for genotyped animals with phenotypes (e.g., reference animals), as well as for (young) genotyped animals without phenotypes. Finally, these 2 single-step genomic models with a residual polygenic effect were proven to be equivalent for estimation of SNP effects, too. Copyright © 2016 American Dairy Science Association. Published by Elsevier Inc. All rights reserved.

  6. Simulation of Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes

    DTIC Science & Technology

    2015-11-01

    induced residual stresses and distortions from weld simulations in the SYSWELD software code in structural Finite Element Analysis ( FEA ) simulations...performed in the Abaqus FEA code is presented. The translation of these results is accomplished using a newly developed Python script. Full details of...Local Weld Model in Structural FEA ....................................................15 CONCLUSIONS

  7. Thermal stress fracture of ceramic coatings

    NASA Technical Reports Server (NTRS)

    Andersson, C. A.

    1983-01-01

    Thermal stress failures of ceramic coatings are discussed in terms of fracture mechanics concepts. The effects of transient and residual stresses on single and multiple cycle failure mechanisms are considered. A specific example of a zirconia thermal barrier coating is presented and its endurance calculated using the proposed relationships.

  8. Residual Stress Reversal in Highly Strained Shot Peened Structural Elements. Degree awarded by Florida Univ.

    NASA Technical Reports Server (NTRS)

    Mitchell, William S.; Throckmorton, David (Technical Monitor)

    2002-01-01

    The purpose of this research was to further the understanding of a crack initiation problem in a highly strained pressure containment housing. Finite Element Analysis methods were used to model the behavior of shot peened materials undergoing plastic deformation. Analytical results are in agreement with laboratory tensile tests that simulated the actual housing load conditions. These results further validate the original investigation finding that the shot peened residual stress had reversed, changing from compressive to tensile, and demonstrate that analytical finite element methods can be used to predict this behavior.

  9. Residual stress analysis of energy-dispersive diffraction data using a two-detector setup: Part I - Theoretical concept

    NASA Astrophysics Data System (ADS)

    Apel, Daniel; Meixner, Matthias; Liehr, Alexander; Klaus, Manuela; Degener, Sebastian; Wagener, Guido; Franz, Christian; Zinn, Wolfgang; Genzel, Christoph; Scholtes, Berthold

    2018-01-01

    A new goniometer setup for energy-dispersive X-ray diffraction is introduced which is based on simultaneous data acquisition with two detectors D1 and D2, both of them freely movable in a horizontal as well as in a vertical plane. From the multitude of measurement configurations that can be realised with this setup, we figured out three efficient concepts which aim at the fast analysis of residual stress depth profiles by combining the diffraction data gathered with the two detectors. The characteristic feature of the first two configurations consists in the vertical (horizontal) positioning of the first (second) detector, which results in a diffraction geometry where the two scattering vectors span a plane that coincides with the X-circle used for sample tilt. Because each detector does see the sample under another viewing angle, both the positive and the negative ψ-branch are covered by just one χ-tilt between 0°and 90°(configuration 1) and 0°and 60°(configuration 2), thus allowing for the simultaneous analysis of the in- and out-of-plane residual stress depth gradients σii(τ) and σi3(τ) (i = 1 , 2), respectively, from data sets dD1hkl(χ) and dD2hkl(χ). The third configuration introduced in this paper is based on a ϕ-rotation of the sample under a constant tilt angle χ and enables a fast and reliable tracing of shear stress fields σi3(τ) (i = 1, 2).

  10. Effect of shot peening on the residual stress and mechanical behaviour of low-temperature and high-temperature annealed martensitic gear steel 18CrNiMo7-6

    NASA Astrophysics Data System (ADS)

    Yang, R.; Zhang, X.; Mallipeddi, D.; Angelou, N.; Toftegaard, H. L.; Li, Y.; Ahlström, J.; Lorentzen, L.; Wu, G.; Huang, X.

    2017-07-01

    A martensitic gear steel (18CrNiMo7-6) was annealed at 180 °C for 2h and at ˜ 750 °C for 1h to design two different starting microstructures for shot peening. One maintains the original as-transformed martensite while the other contains irregular-shaped sorbite together with ferrite. These two materials were shot peened using two different peening conditions. The softer sorbite + ferrite microstructure was shot peened using 0.6 mm conditioned cut steel shots at an average speed of 25 m/s in a conventional shot peening machine, while the harder tempered martensite steel was shot peened using 1.5 mm steel shots at a speed of 50 m/s in an in-house developed shot peening machine. The shot speeds in the conventional shot peening machine were measured using an in-house lidar set-up. The microstructure of each sample was characterized by optical and scanning electron microscopy, and the mechanical properties examined by microhardness and tensile testing. The residual stresses were measured using an Xstress 3000 G2R diffractometer equipped with a Cr Kα x-ray source. The correspondence between the residual stress profile and the gradient structure produced by shot peening, and the relationship between the microstructure and strength, are analyzed and discussed.

  11. DOE Final Report: A Unified Understanding of Residual Stress in Thin Films: Kinetic Models, Experiments and Simulations

    DOE Office of Scientific and Technical Information (OSTI.GOV)

    Chason, Eric

    Thin films are critical for a wide range of advanced technologies. However, the deposited films often have high levels of residual stress that can limit their performance or lead to failure. The stress is known to depend on many variables, including the processing conditions, type of material, deposition technique and the film’s microstructure. The goal of this DOE program was to develop a fundamental understanding of how the different processes that control thin film growth under different conditions can be related to the development of stress. In the program, systematic experiments were performed or analyzed that related the stress tomore » the processing conditions that were used. Measurements of stress were obtained for films that were grown at different rates, different solutions (for electrodeposition), different particle energies (for sputter deposition) and different microstructures. Based on this data, models were developed to explain the observed dependence on the different parameters. The models were based on considering the balance among different stress-inducing mechanism occurring as the film grows (for both non-energetic and energetic deposition). Comparison of the model predictions with the experiments enabled the kinetic parameters to be determined for different materials. The resulting model equations provide a comprehensive picture of how stress changes with the processing conditions that can be used to optimize the growth of thin films.« less

  12. Residual thermal stress control in composite reinforced metal structures. [by mechanical loading of metal component prior to bonding

    NASA Technical Reports Server (NTRS)

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

    1972-01-01

    Advanced composite materials, composed of boron or graphite fibers and a supporting matrix, make significant structural efficiency improvements available to aircraft and aerospace designers. Residual stress induced during bonding of composite reinforcement to metal structural elements can be reduced or eliminated through suitable modification to the manufacturing processes. The most successful method employed during this program used a steel tool capable of mechanically loading the metal component in compression prior to the adhesive bonding cycle. Compression loading combined with heating to 350 F during the bond cycle can result in creep deformation in aluminum components. The magnitude of the deformation increases with increasing stress level during exposure to 350 F.

  13. Effect of far-field stresses and residual stresses incorporation in predicting fracture toughness of carbon nanotube reinforced yttria stabilized zirconia

    NASA Astrophysics Data System (ADS)

    Mahato, Neelima; Nisar, Ambreen; Mohapatra, Pratyasha; Rawat, Siddharth; Ariharan, S.; Balani, Kantesh

    2017-10-01

    Yttria-stabilized zirconia (YSZ) is a potential thermal insulating ceramic for high temperature applications (>1000 °C). YSZ reinforced with multi-walled carbon nanotubes (MWNTs) was processed via spark plasma sintering to produce dense, crack-free homogeneous sample and avoid any degradation of MWNTs when sintered using conventional routes. Despite porosity, the addition of MWNT has a profound effect in improving the damage tolerance of YSZ by allowing the retention of tetragonal phase. However, at some instances, the crack lengths in the MWNT reinforced YSZ matrices have been found to be longer than the standalone counterparts. Therefore, it becomes inappropriate to apply Anstis equation to calculate fracture toughness values. In this regard, a combined analytical cum numerical method is used to estimate the theoretical fracture toughness and quantitatively analyze the mechanics of matrix cracking in the reinforced composite matrices incorporating the effects of various factors (such as far-field stresses, volume fraction of MWNTs, change in the modulus and Poisson's ratio values along with the increase in porosity, and bridging and phase transformation mechanism) affecting the fracture toughness of YSZ-MWNT composites. The results suggest that the incorporation of far-field stresses cannot be ignored in estimating the theoretical fracture toughness of YSZ-MWNT composites.

  14. An Assessment of the Residual Stresses in Low Pressure Plasma Sprayed Coatings on an Advanced Copper Alloy

    NASA Technical Reports Server (NTRS)

    Raj, S. V.; Ghosn, L. J.; Agarwal, A.; Lachtrupp, T. P.

    2002-01-01

    Modeling studies were conducted on low pressure plasma sprayed (LPPS) NiAl top coat applied to an advanced Cu-8(at.%)Cr-4%Nb alloy (GRCop-84) substrate using Ni as a bond coat. A thermal analysis suggested that the NiAl and Ni top and bond coats, respectively, would provide adequate thermal protection to the GRCop-84 substrate in a rocket engine operating under high heat flux conditions. Residual stress measurements were conducted at different depths from the free surface on coated and uncoated GRCop-84 specimens by x-ray diffraction. These data are compared with theoretically estimated values assessed by a finite element analysis simulating the development of these stresses as the coated substrate cools down from the plasma spraying temperature to room temperature.

  15. A methodology to predict damage initiation, damage growth and residual strength in titanium matrix composites

    NASA Technical Reports Server (NTRS)

    Bakuckas, J. G., Jr.; Johnson, W. S.

    1994-01-01

    In this research, a methodology to predict damage initiation, damage growth, fatigue life, and residual strength in titanium matrix composites (TMC) is outlined. Emphasis was placed on micromechanics-based engineering approaches. Damage initiation was predicted using a local effective strain approach. A finite element analysis verified the prevailing assumptions made in the formulation of this model. Damage growth, namely, fiber-bridged matrix crack growth, was evaluated using a fiber bridging (FB) model which accounts for thermal residual stresses. This model combines continuum fracture mechanics and micromechanics analyses yielding stress-intensity factor solutions for fiber-bridged matrix cracks. It is assumed in the FB model that fibers in the wake of the matrix crack are idealized as a closure pressure, and an unknown constant frictional shear stress is assumed to act along the debond length of the bridging fibers. This frictional shear stress was used as a curve fitting parameter to the available experimental data. Fatigue life and post-fatigue residual strength were predicted based on the axial stress in the first intact 0 degree fiber calculated using the FB model and a three-dimensional finite element analysis.

  16. Effects of upper mantle heterogeneities on the lithospheric stress field and dynamic topography

    NASA Astrophysics Data System (ADS)

    Osei Tutu, Anthony; Steinberger, Bernhard; Sobolev, Stephan V.; Rogozhina, Irina; Popov, Anton A.

    2018-05-01

    The orientation and tectonic regime of the observed crustal/lithospheric stress field contribute to our knowledge of different deformation processes occurring within the Earth's crust and lithosphere. In this study, we analyze the influence of the thermal and density structure of the upper mantle on the lithospheric stress field and topography. We use a 3-D lithosphere-asthenosphere numerical model with power-law rheology, coupled to a spectral mantle flow code at 300 km depth. Our results are validated against the World Stress Map 2016 (WSM2016) and the observation-based residual topography. We derive the upper mantle thermal structure from either a heat flow model combined with a seafloor age model (TM1) or a global S-wave velocity model (TM2). We show that lateral density heterogeneities in the upper 300 km have a limited influence on the modeled horizontal stress field as opposed to the resulting dynamic topography that appears more sensitive to such heterogeneities. The modeled stress field directions, using only the mantle heterogeneities below 300 km, are not perturbed much when the effects of lithosphere and crust above 300 km are added. In contrast, modeled stress magnitudes and dynamic topography are to a greater extent controlled by the upper mantle density structure. After correction for the chemical depletion of continents, the TM2 model leads to a much better fit with the observed residual topography giving a good correlation of 0.51 in continents, but this correction leads to no significant improvement of the fit between the WSM2016 and the resulting lithosphere stresses. In continental regions with abundant heat flow data, TM1 results in relatively small angular misfits. For example, in western Europe the misfit between the modeled and observation-based stress is 18.3°. Our findings emphasize that the relative contributions coming from shallow and deep mantle dynamic forces are quite different for the lithospheric stress field and dynamic

  17. X-ray analysis of residual stress gradients in TiN coatings by a Laplace space approach and cross-sectional nanodiffraction: a critical comparison.

    PubMed

    Stefenelli, Mario; Todt, Juraj; Riedl, Angelika; Ecker, Werner; Müller, Thomas; Daniel, Rostislav; Burghammer, Manfred; Keckes, Jozef

    2013-10-01

    Novel scanning synchrotron cross-sectional nanobeam and conventional laboratory as well as synchrotron Laplace X-ray diffraction methods are used to characterize residual stresses in exemplary 11.5 µm-thick TiN coatings. Both real and Laplace space approaches reveal a homogeneous tensile stress state and a very pronounced compressive stress gradient in as-deposited and blasted coatings, respectively. The unique capabilities of the cross-sectional approach operating with a beam size of 100 nm in diameter allow the analysis of stress variation with sub-micrometre resolution at arbitrary depths and the correlation of the stress evolution with the local coating microstructure. Finally, advantages and disadvantages of both approaches are extensively discussed.

  18. Determining the Influence of Granule Size on Simulation Parameters and Residual Shear Stress Distribution in Tablets by Combining the Finite Element Method into the Design of Experiments.

    PubMed

    Hayashi, Yoshihiro; Kosugi, Atsushi; Miura, Takahiro; Takayama, Kozo; Onuki, Yoshinori

    2018-01-01

    The influence of granule size on simulation parameters and residual shear stress in tablets was determined by combining the finite element method (FEM) into the design of experiments (DoE). Lactose granules were prepared using a wet granulation method with a high-shear mixer and sorted into small and large granules using sieves. To simulate the tableting process using the FEM, parameters simulating each granule were optimized using a DoE and a response surface method (RSM). The compaction behavior of each granule simulated by FEM was in reasonable agreement with the experimental findings. Higher coefficients of friction between powder and die/punch (μ) and lower by internal friction angle (α y ) were generated in the case of small granules, respectively. RSM revealed that die wall force was affected by α y . On the other hand, the pressure transmissibility rate of punches value was affected not only by the α y value, but also by μ. The FEM revealed that the residual shear stress was greater for small granules than for large granules. These results suggest that the inner structure of a tablet comprising small granules was less homogeneous than that comprising large granules. To evaluate the contribution of the simulation parameters to residual stress, these parameters were assigned to the fractional factorial design and an ANOVA was applied. The result indicated that μ was the critical factor influencing residual shear stress. This study demonstrates the importance of combining simulation and statistical analysis to gain a deeper understanding of the tableting process.

  19. Evaluation of the residual stresses in 95wt%Al2O3-5wt% SiC wear protection coating using X-Ray diffraction technique

    NASA Astrophysics Data System (ADS)

    Mahmoud, Adel K.; Hammoudi, Zaid S.; Student Samah Rasheed, M. Sc.

    2018-02-01

    This paper aims to measuring the residual stresses practically in wear protection coatings using the sin2ψ method according to X-ray diffraction technique. The wear protection coatings used in this study was composite coating 95wt% Al2O3-5wt% SiC, while bond coat was AlNi alloy produced by using flame spraying technique on the mild steel substrate. The diffraction angle, 2θ, is measured experimentally and then the lattice spacing is calculated from the diffraction angle, and the known X-ray wavelength using Bragg’s Law. Once the dspacing values are known, they can be plotted versus sin2ψ, (ψ is the tilt angle). In this paper, stress measurement of the samples that exhibit a linear behavior as in the case of a homogenous isotropic sample in a biaxial stress state is included. The plot of dspacing versus sin2ψ is a straight line which slope is proportional to stress. On the other hand, the second set of samples showed oscillatory dspacing versus sin2ψ behaviour. The oscillatory behaviour indicates the presence of inhomogeneous stress distribution. In this case the X-ray elastic constants must be used instead of Young’s modulus (E) and Poisson ratio (ν)values. These constants can be obtained from the literature for a given material and reflection combination. The value of the residual stresses for the present coating calculated was compressive stresses (-325.6758MPa).

  20. Transient and residual stresses in a pressable glass-ceramic before and after resin-cement coating determined using profilometry.

    PubMed

    Isgró, G; Addison, O; Fleming, G J P

    2011-05-01

    The effect of heat-pressing and subsequent pre-cementation (acid-etching) and resin-cementation operative techniques on the development of transient and residual stresses in different thicknesses of a lithium disilicate glass-ceramic were characterised using profilometry prior to biaxial flexure strength (BFS) determination. 60 IPS e.max Press discs were pressed and divested under controlled conditions. The discs were polished on one surface to thicknesses of 0.61±0.05, 0.84±0.08, and 1.06±0.07 mm (Groups A-C, respectively). The mean of the maximum deflection (acid-etching and resin-coating was determined using high resolution profilometery prior to BFS testing. Paired sample t-tests were performed (p<0.05) on the 20 individual samples in each group (Groups A-C) for each comparison. Differences between the baseline quantification and resin-cement coating deflection values and BFS values for Groups A-C were determined using a one-way ANOVA with post hoc Tukey tests (p<0.05). Baseline quantification for Groups A-C identified no significant differences between the group means of the maximum deflection values (p=0.341). Following HF acid-etching, a significant increase in deflection for all groups (p<0.001) was identified compared with the baseline quantification. Additionally, resin-cement coating significantly increased deflection for Group A (p<0.001), Group B (p<0.001) and Group C (p=0.001) specimens for the individual groups. The increased deflection from baseline quantification to resin-cement coating was significantly different (p<0.001) for the three specimen thicknesses, although the BFS values were not. The lower reported baseline quantification range of the mean of the maximum deflection for the IPS e.max(®) Press specimens was predominantly the result of specimen polishing regime inducing a tensile stress state across the surface defect integral which accounted for the observed surface convexity. Acid-etching and resin-cementation had a significant