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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

On the roles of welding residual stresses in determination of fracture toughness in austenitic stainless steel SUS 304 pipeline girth welds

Welding residual stresses especially the high tensile stresses are proved to have negative impacts on the fatigue and fracture behaviors of welded structures. In this study, a virtual fabrication of test specimens from welding process to specimen preparation was carried out by numerical simulation. An austenitic stainless steel multi-pass pipe welding was simulated by transient thermal–mechanical finite element analysis, the residual stresses were then mapped into the test specimen to evaluate fracture toughness. The findings in this study confirmed that, residual stress can be high in a sub-sized compact tensile specimen, which may accelerate or hinder the crack propagation during actual fatigue and fracture tests as reported in recent years. The influence of the cutting location and orientation of the specimen on fracture performance was investigated systematically to provide a fundamental understanding of welding residual stress and necessary insights into the specimen preparation procedure. Considering the limitation of measuring techniques and the complexity of the stress distribution, the developed numerical model can be a very useful tool to elucidate the stress evolution and quantify the effect of remaining welding stress on fracture toughness.

Fracture behavior↗
NASA NTRS1991

Simplified micromechanical equations for thermal residual stress analysis of coated fiber composites

The fabrication of metal matrix composites poses unique problems to the materials engineer. The large thermal expansion coefficient (CTE) mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix (F/M) interface which could lead to premature matrix cracking during cooldown. Fiber coatings could be used to reduce thermal residual stresses. A simple closed form analysis, based on a three phase composite cylinder model, was developed to calculate thermal residual stresses in a fiber/interphase/matrix system. Parametric studies showed that the tensile thermal residual stresses at the F/M interface were very sensitive to the CTE and thickness of the interphase layer. The modulus of the layer had only a moderate effect on tensile residual stresses. For a silicon carbide titanium aluminide composite, the tangential stresses were 20 to 30 pct. larger than the axial stresses, over a wide range of interphase layer properties, indicating a tendency to form radial matrix cracks during cooldown. Guidelines for the selection of appropriate material properties of the fiber coating were also derived in order to minimize thermal residual stresses in the matrix during fabrication.

Naik, R. A.↗
NASA NTRS1992

The effects of uneven fiber spacing on thermal residual stresses in a unidirectional SCS-6Ti-15-3 laminate

High residual stresses develop in SCS-6/Ti-15-3 composites during cooldown from the fabrication temperature; these residual stresses can effect the mechanical and physical properties of the composite. Discrete fiber-matrix finite element models were used to study the residual stresses due to the temperature change during the fabrication process, including the effects of uneven fiber spacing, the free surface, and increased fiber volume fractions. To accurately model the effects of the free surface, it is only necessary to model one fiber through the thickness. Below the first ply, the analysis predicts stress distributions that are identical to the infinite array predictions. For uneven fiber space less then 0.042 mm in an interior ply, the maximum hoop stress was predicted to occur between fibers within a ply and to increase as the fiber spacing decreased. The maximum hoop stress correlated well with the observed radial cracking between fibers. For the case of touching fibers, the analysis predicted tensile radial stresses at the fiber-matrix debonding during the fabrication cooldown. Identical trends were predicted for uneven fiber spacing in surface plies with slightly greater values of maximum stresses. The analysis predicted matrix yielding to occur upon cooldown when the edge-to-edge fiber spacing was less than or equal to 0.022 mm. The stress distributions predicted for increasing fiber volume fractions were similar to those predicted for decreasing the fiber spacing for two adjacent fibers within a ply.

Bigelow, C. A.↗
DOE OSTI2018

Experimental and FEM Study of Residual Stresses During Ultra-Precision Turning of Aluminum 2024-T3

Aluminum 2024-T3 is commonly used in ultra-precision turning. In this study, the residual stresses of aluminum 2024-T3 were investigated by the finite element method (FEM) and a series of cutting experiments. The effects of depth of cut, cutting speed, rake angle and tool edge radius on the residual stresses were discussed by FEM. Moreover, an orthogonal simulation experiment was also conducted. The order of the strong-to-weak sequence of factors on residual stresses in cutting direction is the rake angle, tool edge radius, depth of cut and cutting speed. The cutting experiments were conducted and the surface residual stresses in the cutting direction were measured by X-ray diffraction. The experimental results showed that increasing cutting speed and decreasing tool edge radius can reduce the surface residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Residual Stresses Affect Cell Fragment Movement

Predictive modeling tools such as the finite element method can be of tremendous help in assessing the reliability and long-term performance of photovoltaic modules. In order to obtain accurate results, the proper modeling of materials and manufacturing processes are of utmost importance. Module fabrication introduces thermo-mechanical stresses inside the module laminate, which need to be accounted for as residual stresses in finite element simulations. We found that cell fragment movement and crack opening displacements of fractured silicon cells within modules are affected by those residual stresses. Cell cracking remains a challenging topic in assessing the reliability and durability of damaged modules. Hence, accurately quantifying the separation and movement between cell fragments creates the foundation for establishing reliable lifetime and performance assessments of fractured silicon modules. Here, we present a modeling approach that uses upper and lower bounds to accurately account for the residual stresses introduced by the module lamination process. We designed a four-point flexure coupon test of a laminated, fractured silicon strip to validate our numerical results and found good agreement between our modeling methodology and the experimental data. Finally, we discuss the implications of the residual stresses on the normal crack opening and metallization wear-out of fractured silicon cells.

14 SOLAR ENERGY↗
NASA NTRS1997

Determination of Residual Stress in Composite Materials Using Ultrasonic Waves

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 stresses. It is based on the generalized self-consistent multiple scattering model. Calculation results for longitudinal and shear ultrasonic wave velocities propagating perpendicular to the fibers direction in SCS-6/Ti composite with and without residual stresses are presented. They show that velocity changes due to presence of stresses are of order 1%.

Rokhlin, S. I.↗
DOE OSTI2025

Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement

Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. In conclusion, the results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.

Residual stress↗
DOE OSTI2018

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

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.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Measurement of Residual Stresses in Different Thicknesses of Laser Shock Peened Aluminium Alloy Samples

This study focused on depth-resolved residual stress results determined with a number of complementary techniques on Laser Shock Peening (LSP) treated aluminium alloy 7075-T651 samples with different thicknesses (6 mm and 1.6 mm). Samples were prepared from a single commercially produced rolled plate that was then treated with LSP. Residual stresses were measured using Laboratory X-Ray Diffraction (LXRD), Incremental Hole Drilling (IHD), Neutron Diffraction (ND) and Synchrotron XRD (SXRD). The LSP treatment resulted in the establishment of compressive residual stresses that varied rapidly in the near surface region. The compressive stresses extended up to 1.5 mm in depth in the 6 mm thick sample. Some surface stress relaxation was observed in the first 25 μm, but substantially large stresses existed at 50 mu m. Finally, this investigation strongly motivated why residual stress profiles should be obtained using a variety of techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Friction-stir-welding (FSW) has gained importance as an effective way to join dissimilar materials due to its solid-state nature. However, FSW produces substantial residual stresses in aluminum welding, often deteriorating the component's structural performance and reliability. In the current study, the d-spacing (inter-atomic distance) of several locations on a battery tray and stress-free reference samples are measured with neutron diffraction to calculate the residual stresses in a lap 6061 to A365 dissimilar friction-stir-weld. Furthermore, the present study connects the measured residual stress to microstructure properties through electron backscatter diffraction (EBSD) and optical microscopy analyses. The EBSD results indicate that the FSW operation affects the grains’ orientation, thereby producing location-specific directionally varying elasticity across the weldment. Further, this varied elasticity creates unique d-spacing profiles even in the stress-free material. Additionally, the resulting stressed and stress-free d-spacing profiles show dependencies on the FSW tool geometry, traverse direction, and rotational direction. Lastly, this study suggests that the final component residual stress can be influenced by the sequence of multi-pass welds contributing to a rise in temperature in the presence of a completed weld relaxing its residual stress.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Study of Residual Stresses in Hybrid Laser Arc and Submerged Arc-Welded 10-mm-Thick Low-Carbon Steel Plates

Offshore structures are constantly exposed to a multihazard marine environment that threatens their structural integrity. This imposes a high risk for extensive structural failures while various deterioration mechanisms may degrade the available capacity of the structures. Thus, no reliable decisions can be reached regarding design, operation, and survivability of the structures unless a deep comprehension of their fatigue performance is available, including welding-induced residual stresses. In particular, the continuous increase in size of the weldments for the offshore wind industry needs special attention with regard to welding-induced residual stresses, as they can reduce fatigue life, promote distortion, and contribute to stress corrosion cracking. Thus, the current design methods and increased structural dimensions as well as new design and manufacturing methods need to be inspected, understood, and optimized. Related to this, there is a growing need for evaluation of the effect of welding methods with various heat input density distributions. This article deals with the influence of welding method on the welding-induced residual stresses in 10-mm-thick low-carbon structural steel plates. The residual stresses are investigated in hybrid laser-arc welded and submerged arc butt-welded steel plates by means of experimental temperature profile measurements and neutron diffraction measurements and in accordance with existing production procedures. The residual stresses were measured at three different depths in the plates. The goal of the analysis is to gain a comprehensive understanding of the distribution and development of residual stresses in relation to the welding method for better control of the residual stresses and distortion. Furthermore, the repeatability of the neutron diffraction measurements is also investigated and reported in this article.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Exploring the Cooling Process for Residual Stress Reduction in Dissimilar Welds

Dissimilar metal welds are currently used in various industry applications; however, a significant number of failures have been reported in these joints due to the existence of large tensile residual stresses induced by arc welding processes. Hence, it is crucial to reduce or eliminate such residual stresses in dissimilar metal welds. Recently, modern techniques such as CO 2 rapid cooling have received attention by scholars to reduce residual stress in similar metal welds. Nevertheless, the effectivity of this technique has not been explored in dissimilar metal welds. In this paper, the impact of in-situ rapid local cooling in dissimilar metal welds is studied experimentally. The residual stresses of CO 2 -cooled welds were measured using the neutron diffraction technique. The effect of rapid cooling on the microstructure of the weld and heat-affected zones were examined. Finally, it is shown that for certain cases, in-situ rapid cooling during the arc welding process can minimize tensile residual stresses in dissimilar metal welds.

42 ENGINEERING↗
DOE OSTI2023

Microstructure and Residual Stress in Functionally Graded 316L Stainless Steel/Inconel 625 Alloys Fabricated by Direct Energy Deposition

Functionally graded materials (FGMs) provide a unique solution to combine distinct properties within a single component to enhance its overall performance. Understanding the microstructure and residual stress distribution is particularly important as the material dissimilarity in FGMs can result in high residual stress that affects the mechanical integrity of structural components. Here, this work aims to study the microstructure and residual stress of additively manufactured FGMs and the effects of isothermal annealing. In this study, 316L stainless steel/Inconel 625 FGMs were built by direct energy deposition, and characterized by optical and electron microscopy as well as synchrotron-based X-ray diffraction. Our study reveals that thermal annealing at 500°C for 3 h has minimal effects on the microstructure and chemistry of the graded materials, but effectively relieves the residual stress and leads to a uniform distribution of residual stress.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Method and apparatus for determination of material residual stress

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.

Chern, Engmin J.↗
DOE OSTI2019

Numerical Simulation of Residual Stresses in Multipass Gas Metal Arc-Welded Joints of Thick Aluminum Alloy Plates

Numerical simulation was utilized to investigate the residual stresses in the multipass gas metal arc-welded joints of high-strength Al-Zn-Mg alloy plates. In order to elevate the reliability of numerical simulation, the heat source model, parameters characterizing the thermal and mechanical properties, boundary conditions, material constitutive model and finite element meshing were discussed in detail. As a novelty of this paper, the modified Arrhenius constitutive equation of the base material and the filled material was obtained according to the results of high-temperature tensile tests. Distributions of stress on the upper and bottom surface of the joint were obtained based on numerical simulation. Special attention was paid to the evolutions of local residual stress on the bottom surface of the joint, and it’s found that residual stresses on the bottom surface of the joint were almost unchanged after the weld seam approached a certain thickness. Blind-hole method and x-ray method were adopted to detect the residual stresses on the surfaces to verify the accuracy of the results obtained by numerical simulation.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Residual stresses in angleplied laminates and their effects on laminate behavior

NASA Lewis Research Center research in the field of composite laminate residual stresses is reviewed and summarized. The origin of lamination residual stresses, evidence of their presence, experimental methods for measuring them, and theoretical methods for predicting them are described. Typical results are presented which show the magnitudes of residual stresses in various laminates including hybrids and superhybrids, and in other complex composite components. Results are also presented which show the effects of lamination residual stresses on laminate warpage and on laminate mechanical properties including fracture stresses. Finally, the major findings and conclusions derived therefrom are summarized.

Chamis, C. C.↗
DOE OSTI2026

Mapping the Residual Stress Distribution in Polycrystalline Quartz Tiger's Eye Using Raman Spectroscopy

Stress distribution maps in polycrystalline materials are needed to reveal stress pathways caused by short‐and long‐range interactions of crystallites. Stress induced changes to wavenumbers in Raman spectroscopy is a well‐known phenomenon that occurs when a crystalline material undergoes elastic strain. Using spatially resolved Raman spectroscopy, we have developed a technique to experimentally measure grain‐scale residual stresses across a sample of polycrystal quartz Tiger's Eye. The results of this technique are validated using multiple criteria, including evaluation of the residual stress map itself and the accuracy of the measurements taken. The residual map of Tiger's Eye shows striking similarity to observed characteristics of other polycrystalline residual stress distributions, revealing heterogenous areas of high and low magnitude stresses. The stress magnitudes are consistent with residual stress magnitudes previously measured from polycrystalline quartz. Characterization of Tiger's Eye quartz also revealed the geometric nature of the iron oxide inclusions, not previously observed in Tiger's Eye quartz. With this technique, we present a residual stress map of Tiger's Eye quartz that shows with accuracy a heterogeneous stress state with inter‐ and intra‐granular detail.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Investigation of residual stress distribution in wire-arc directed energy deposited refractory molybdenum alloy utilizing numerical thermo-mechanical analysis and neutron diffraction method

Directed energy deposition (DED), a metal additive manufacturing (AM) technique, offers higher deposition rates and energy efficiency, making it suitable for fabricating components from refractory molybdenum alloys, such as molybdenum-titanium-zirconium (TZM). However, large thermal gradients and non-equilibrium thermal cycles in DED could generate high residual stress in the component, potentially deteriorating quality and performance. Thus, this study aims to investigate residual stress generation and its distribution in wire-arc DED of TZM thin-wall, utilizing thermo-mechanical analysis and high-fidelity neutron diffraction (ND) method. Two interpass temperatures (50°C and 200°C) have been considered to investigate their impact on residual stress formation. During experiments, in-situ thermal data has been recorded using thermocouples, which have been utilized for calibrating the thermal model. Thermocouple data shows a good agreement with the simulation results, having a difference of less than 10 %. Post-deposition part deformation has been observed, which is measured using a coordinate measuring machine, showing maximum values of 0.93 mm and 0.78 mm for interpass temperatures of 50°C and 200°C, respectively. Numerical predictions of distortion deviated by less than 15% from the experimental results. ND measurement and simulation results indicate that residual stress magnitude and evolution vary across the TZM deposits, revealing microstructural anisotropy in both conditions. Notably, lower interpass temperatures resulted in higher residual stresses, confirmed by experimental and simulation data. Further, this study demonstrated that an integrated experimental and thermo-mechanical analysis can potentially reveal the temperature history, part deformation, and residual stress formation in wire-arc DED TZM alloy.

36 MATERIALS SCIENCE↗