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Results for “RESIDUAL STRESSES”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

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]

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. This 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.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Verification and validation of residual stresses in composite structures

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, the objectives of the presented work are to demonstrate an efficient method for simulating residual stresses in composite parts, as well as the potential value of statistical methods during analyses for which material properties are unknown. Specifically, a simplified residual stress modeling approach is implemented within Sandia National Laboratories’ SIERRA/SolidMechanics code. Concurrent with the model development, bi-material composite structures are designed and manufactured to exhibit significant residual stresses. Then, the presented modeling approach is rigorously verified and validated through simulations of the bi-material composite structures’ manufacturing processes, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.

42 ENGINEERING↗
DOE OSTI2020

Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here we report an initial reproducibility experiment focused on contour method data analysis and residual stress calculation. The experiment uses surface topography data from a physical process simulation of elastic-plastic beam bending. The simulation provides surface topography, for input to the contour method data analysis, as well as a known residual stress field with 130 MPa peak magnitude. Additionally, to increase realism, noise and specific artifacts are added to the topography data. A group of participants received the topography data (without the known residual stress), independently analyzed the data, and submitted results as a two-dimensional residual stress field. Analysis of submissions provides a group average residual stress field and the spatial distribution of reproducibility standard deviation. The group average residual stress agrees with the known stress in magnitude and spatial trend. The reproducibility standard deviation ranges from 2 to 54 MPa over the measurement plane, with an average of 5.4 MPa. Reproducibility standard deviation is smaller in the cross-section interior (≤ 5 MPa), modest near local extrema in the stress field (5 to 10 MPa), and larger near the cross-section boundaries (10 to 30 MPa). Overall, the largest values of reproducibility standard deviation (up to 54 MPa) occur in limited areas where artifacts had been added to the topography data; while some participants identified and removed these artifacts, some did not, leading to systematic differences that elevated the standard deviation.

42 ENGINEERING↗
DOE OSTI2018

Survey of DAKOTA's V&V Capabilities in the Simulation of Residual Stresses in a Simple Composite Structure

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses can result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, a process modeling methodology was developed and implemented into Sandia National Laboratories' SIERRA/SolidMechanics code. This method can be used to predict the process-induced stresses in any composite structure, regardless of material composition or geometric complexity. However, to develop confidence in these predictions, they must be rigorously validated. Specifically, sensitivity studies should be completed to define which model parameters are critical to the residual stress predictions. Then, the uncertainty associated with those critical parameters should be quantified and processed through the model to develop stress-state predictions encompassing the most important sources of physical variability. Numerous sensitivity analysis and uncertainty quantification methods exist, each offering specific strengths and weaknesses. Therefore, the objective of this study is to compare the performance of several accepted sensitivity analysis and uncertainty quantification methods during the manufacturing process simulation of a composite structure. The examined methods include simple sampling techniques as well as more sophisticated surrogate approaches. The computational costs are assessed for each of the examined methods, and the results of the study indicate that the surrogate approaches are the most computationally efficient validation methods and are ideal for future residual stress investigations.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Consumable development to tailor residual stress in parts fabricated using directed energy deposition processes

Distortion and residual stresses are major challenges that limit the ability to fabricate large scale structures using Additive Manufacturing (AM). Researchers worldwide are evaluating techniques to induce compressive residual stress in the parts via intermittent rolling. While reasonable success has been documented, the idea of lowering the martensite start temperature to induce compressive stresses has not been evaluated in the context of AM, despite demonstrated success by the welding community. This study validates the hypothesis that, by a proper selection of materials and process parameters, one may effectively reduce distortion and induce a compressive residual stress in AM parts. Using neutron diffraction to measure residual stresses in parts, we demonstrate that, in addition to selection of the correct materials, the inter pass temperature plays a major role in controlling the residual stress evolution. The observations relating to the residual stresses are rationalized based on a microstructural evolution in these samples. Based on this preliminary study, a strategy to fabricate large structures with minimal distortion and residual stress is outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2018

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

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.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Measuring the residual stress and stress-corrosion cracking susceptibility of additively manufactured 316L by ASTM G36-94

Residual stress is a contributor to stress-corrosion cracking (SCC) and a common byproduct of additive manufacturing (AM). In this work, the relationship between residual stress and SCC susceptibility in laser powder bed fusion AM 316L stainless steel was studied through immersion in saturated boiling magnesium chloride per ASTM G36-94. The residual stress was varied by changing the sample height for the as-built condition and additionally by heat treatments at 600, 800, and 1200 °C to control, and in some cases reduce, residual stress. In general, all samples in the as-built condition showed susceptibility to SCC with the thinner, lower residual stress samples showing shallower cracks and crack propagation occurring perpendicular to melt tracks due to local residual stress fields. The heat-treated samples showed a reduction in residual stress for the 800 and 1200 °C samples. Both were free of cracks after >300 hours of immersion in MgCl 2 , while the 600 °C sample showed similar cracking to their as-built counterpart. Geometrically necessary dislocation (GND) density analysis indicates that the dislocation density may play a major role in the SCC susceptibility.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A Generalized Stress Inversion Approach With Application to Residual Stress Estimation

In this work develop a generalized stress inversion technique (or the generalized inversion method) capable of recovering stresses in linear elastic bodies subjected to arbitrary cuts. Specifically, given a set of displacement measurements found experimentally from digital image correlation (DIC), we formulate a stress estimation inverse problem as a partial differential equation-constrained optimization problem. We use gradient-based optimization methods, and we accordingly derive the necessary gradient and Hessian information in a matrix-free form to allow for parallel, large-scale operations. By using a combination of finite elements, DIC, and a matrix-free optimization framework, the generalized inversion method can be used on any arbitrary geometry, provided that the DIC camera can view a sufficient part of the surface. We present numerical simulations and experiments, and we demonstrate that the generalized inversion method can be applied to estimate residual stress.

42 ENGINEERING↗
DOE OSTI2022

Smart material based multilayered microbeam structures for spatial self-deployment and reconfiguration: A residual stress approach

Alleviation of the potentially damaging effects induced by residual stresses was comprehensively investigated in previous research. Here, this paper, however, presents a spatially self-deployable and reconfigurable multilayered microbeam which takes advantage of residual stresses and shape memory effects. Reconfigurable mechanism of a typical four-layered microbeam composed of Pt\Ni 50 Ti 50 \Ni 50 Ti 50 \Pt is introduced, followed by analytical modeling of the maximum distance of the self-deployed gap as functions of variable structural and material parameters, including compressive residual stress in Pt layers and tensile residual stress in Ni 50 Ti 50 layers. Analytical solutions given by the static model agree well with the results obtained via finite element models (FEMs). Fabrication, characterization, and in-situ experiments were carried out to validate the feasibility of deployment of the as-released four-layered microbeam. The maximum distance of the gap was measured to be 41.39 μm at 20 °C, which could be increased to 51.73 μm thanks to controllable reconfiguration driven by shape memory effects. Theoretical analysis of such self-deployment and reconfiguration suggested a tensile residual stress increase by 52 MPa in Ni 50 Ti 50 layers. The multilayered microbeam structure with capabilities of self-deployment and reconfiguration offers great potential for various emerging applications, such as micro robotics, medical drug delivery devices, and intelligent chip scale spacecraft.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Geometrical effects on the measured neutron residual stress in additively manufactured cold spray AA6061

Aluminum cold spray additive builds were made with varying wall widths and geometries to explore the effects of build geometry on residual stress development in the additively sprayed material. Deposition rates of over 750 g/hr were achieved without any cracking or delamination of the additively manufactured components. Neutron residual stress measurements revealed a maximum tensile residual stress of 41 MPa at the interface of the substrate and a maximum compressive residual stress of −35 MPa in the cold sprayed material. While there was not found to be significant residual stress changes between the cold sprayed walls, the cold sprayed cylinder had varying residual stress throughout the diameter with the outer diameter having a higher tensile residual stress than the interior. The low residual stress and minimal geometrical dependency demonstrate further part size is possible without concerns for component failure in AA6061. The application of common coating residual stress models to full scale additive builds is evaluated and discussed. The lack of residual stress evolution was studied by in-situ coating property measurement that revealed that the deposition stress of the AA6061 sprays reduced with increased layer thickness. In conclusion, this study provides insight into the evolution of residual stress in cold spray additive components and how both the mechanics and material responses differ from coatings.

Additive manufacturing↗
DOE OSTI2024

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

A recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness. Herein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness. Near-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness. Measured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter. The new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

42 ENGINEERING↗