Experimental determination of residual stresses in an orthotropic material.
Residual stress distribution in two orthogonal directions of isotropic or orthotropic material, using computerized technique
Frick, R. P.↗
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Lamination residual stresses in multilayered fiber composites
Residual stresses arising from fabrication processes in laminates
Chamis, C. C.↗
ETP-0492, Measured Residual Stresses in CYL S/N 53 Fretted Area
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.
Webster, Ronald L.↗
Residual Stress Distribution in a Hydroformed Advanced High Strength Steel Component: Neutron Diffraction Measurements and Finite Element Simulations
Today’s automotive industry is witnessing increasing applications of advanced high strength steels (AHSS) combined with innovative manufacturing techniques to satisfy fuel economy requirements of stringent environmental regulations. The integration of AHSS in novel automotive structure design has introduced huge advantages in mass reduction while maintaining their structural performances, yet several concerns have been raised for this relatively new family of steels. One of those concerns is their potentially high springback after forming, which can lead to geometrical deviation of the final product from its designed geometry and cause difficulties during assembly. From the perspective of accurate prediction, control and compensation of springback, further understanding on the effect of residual stress in AHSS parts is urged. In this work, the residual stress distribution in a 980GEN3 steel part after hydroforming is investigated via experimental and numerical approaches. A non-destructive neutron diffraction technique is adopted to reveal the residual stress profiles across a 94-degree tube bending radius section of the hydroformed part. The finite element analysis (FEA) is also conducted to simulate the hydroforming and the subsequent unloading processes to predict the residual stress distribution within the same region. The correlation between experimental and simulation results is presented and the effectiveness of the FEA model for residual stress prediction is discussed. Findings in this study set the basis for springback analysis with improved accuracy and reliability.
Huang, Lu↗
Evolution of Microstructure, Residual Stress, and Tensile Properties of Additively Manufactured Stainless Steel Under Heat Treatments
This study investigated the microstructure, residual stress and tensile properties of the directed energy deposited stainless steel 316L (SS316L) under thermal annealing. Microstructure characterization shows the as-printed sample has laser-generated patterns where dendritic structure is observed at the edge of the patterns and cellular structure dominates the interior region. Here, the thermal annealing at 983 and 1093°C effectively removes the dendritic/cellular structures. Synchrotron X-ray diffraction reveals that the as-fabricated SS316L exhibits compressive residual stress of -197.4 MPa. The stress is greatly relieved to -53.8 MPa after annealing at 1093°C. The room temperature tensile testing indicates that the yield strength and ultimate tensile strength drop from 378 and 502 MPa in the as-printed sample to 258 and 446 MPa in the annealed samples (1093°C), respectively. Our study provides insights into the relationship between microstructure, residual stress, and tensile properties of laser additive manufactured SS316L.
36 MATERIALS SCIENCE↗
Photoluminescence Spectroscopy to Determine Residual Stresses in Glass-to-Metal Seals
In components with two materials, such as glass-to-metal (GtM) seals, residual stress can reduce long-term reliability. Therefore, it is important to be able to accurately measure residual stress within these components. The residual stress can be from a large strain due to the mismatch of thermo-physical response of the two materials or a small strain due to stress and/or structural relaxation. Both modeling and experimental measurements were conducted on multiple GtM seals constructed with CGI 930 glass with purposely added alumina particles. The alumina particles have an established Cr fluorescence pattern and the shift in position of these peaks can accurately measure the strain of the alumina crystals. Photoluminescence spectroscopy (PLS) technique was utilized due to its non-destructive nature and high spatial resolution. PLS scans of these components were analyzed and compared to the models developed previously.
36 MATERIALS SCIENCE↗
Residual stress in high modulus carbon fibers
The modulus and residual strain in carbon fibers are measured by successively electrochemically milling away the fiber surface. Electrochemical etching is found to remove the carbon fiber surface very uniformly, in contrast to air and wet oxidation. The precision of fiber diameter measurements is improved by using a laser diffraction technique instead of optical methods. More precise diameter measurements reveal that past correlations of diameter and fiber modulus are largely measurement artifact. The moduli of most carbon fibers decrease after the outer layers of the fibers are removed. Owing to experimental difficulties, the moduli and strengths of the fibers at their centers are not determined, and moduli are estimated on the basis of microstructure. The calculated residual stresses are found to be insensitive to these moduli estimates as well as the exact form of regression equation used to describe the moduli and residual strain distributions. Axial compressive residual stresses are found to be very high for some higher modulus carbon fibers. It is pointed out that the compressive stress makes the fibers insensitive to surface flaws when loaded in tension but it may initiate failure by buckling when loaded in compression.
Chen, K. J.↗
Evaluation of a thermomechanical model for prediction of residual stress during laser powder bed fusion of Ti-6Al-4V
The build-up of residual stresses in a part during laser powder bed fusion provides a significant limitation to the adoption of this process. These residuals stresses may cause a part to fail during a build or fall outside the specified tolerances after fabrication. In the present work a thermomechanical model is used to simulate the build process and calculate the residual stress state for Ti–6Al–4V specimens built with continuous and island scan strategies. A layer agglomeration, or lumping, approach is used to speed up the computations. A material model is developed to naturally capture the strain-rate dependence and annealing behavior of Ti–6Al–4V at elevated temperatures. Conclusions from the thermomechanical simulations showed good agreement with synchrotron X-ray diffraction measurements used to determine the residual elastic strains in these parts. Yet, the experimental measurements showed higher residual strains for the specimen built with an island scan strategy; a trend not fully captured by the simulations. Parameter studies were performed to fully understand the advantages and limitations of the current simulation methodology. Reasons for both the computational and experimental findings are discussed.
36 MATERIALS SCIENCE↗
Residual stresses in angleplied laminates and their effects on laminate behavior
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.
Chamis, C. C.↗
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 mismatch between the fiber and matrix leads to high tensile residual stresses at the fiber/matrix interface which could lead to premature matrix cracking during cooldown. Fiber coating 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/interface/matrix system. Guidelines, in the form of simple equations, for the selection of appropriate material properties of the fiber coating, were also derived to minimize thermal residual stresses in the matrix during fabrication.
Naik, Rajiv A.↗
MOOSE Optimization Module Overview: Application to Residual Stress Inversion in Nuclear Fuel Plates
Manufacturing methods, material selections and unique plate geometries used in low enriched uranium plate fuels for the High Performance Research Reactor (HPRR) have led to concerns about the residual stresses effect on bond strength of the fuel/cladding interfaces and overall fuel performance under irradiation. The current HPRR plate fuel test program performed residual stress calculations using the contour method with experimental displacement data obtained by incrementally cutting the plate fuel. In this work, we use a gradient based inverse optimization module developed within the MOOSE framework to estimate normal and shear residual stresses within the plate fuels using displacement data taken from a cut placed in the HPRR fuel plate. These results are verified against residual stress calculations obtained from the contour method. The inversion protocol used in this work utilizes two meshes to separately discretize the physics and parameter space. This allows a fine mesh to be used to fully resolve the physics and geometry of the forward problem. A coarser mesh is used to resolve the parameter space with spatially varying mesh density determined from a sensitivity analysis. The adaptive resolution of the parameter space essentially has the effect of regularization as it is designed to achieve the bias-variance tradeoff.
42 ENGINEERING↗
Neutron Residual Stress Mapping of Repaired Spent Nuclear Fuel Welded Stainless-Steel Canisters
Stress corrosion cracking (SCC) caused by atmospheric deposition and deliquescence of aggressive compounds such as chloride-containing salts or oxidized sulfur species may pose a potential issue to the extended service life of spent nuclear fuel (SNF) storage canisters. When a chemically susceptible material is exposed to a hostile environment (e.g., coastal salt air) for a sufficient length of time, SCC may occur at locations on the canister which have undergone high tensile residual stress. These locations are often found in weld zones and the heat-affected zones (HAZ) of welded joints. Ideally, these cracks could be repaired by traditional fusion welding techniques, but the highly localized heat input of the repair welding may introduce additional high tensile residual stress and could increase the risk for future SCCs. This paper presents the results of neutron residual stress mapping of as-welded and repaired stainless steel specimens. The as-welded specimens were provided by Sandia National Laboratories from a canister mock-up manufactured using procedures similar to those used for actual canister production. ASME-qualified gas-tungsten arc welding (GTAW) was used to repair the specimens, and post-repair residual stresses were measured using neutron diffraction at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR). As-welded and repaired specimen residual stress distributions are evaluated and compared.
Chatzidakis, Stylianos↗
3D mapping of residual stresses in growing grains of partially recrystallized Gum Metal
The crystallographic orientations and residual stresses within recrystallizing grains in partially recrystallized beta titanium-Gum Metal-were examined non-destructively in 3D using synchrotron Differential Aperture X-ray Microscopy. Contrary to common assumptions, significant local stresses and stress variations are observed within the recrystallizing grains. The results reveal that the development of these local residual stresses depends on the plastic deformation mode and material's elastic constants, rather than grain properties such as size and orientation, or even the material's yield stress. This work provides insights valuable for the design of advanced materials with heterogeneous microstructures.
36 MATERIALS SCIENCE↗
Residual stresses in continuous graphite fiber Al metal matrix composites
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.
Park, Hun Sub↗
Resonance ultrasound prediction of residual stress within a hybrid layer for additively manufactured samples
Hybrid additive manufacturing (AM) involves secondary processes or energy sources to alter specified locations within the build volume. Each hybrid step can refine the grain size, increase dislocation density, or modify residual stresses. Typically, the changes in mechanical properties are not confined within a single layer but have a compounding effect on preceding layers. Existing methods of measuring AM residual stress are limited in terms of their sensitivity, or they are destructive measurements. We propose using resonant ultrasound spectroscopy (RUS) to measure the residual stress in hybrid-AM components noninvasively, based on changes to the resonances, compared to a stress-free component. In this paper, we use finite element models to simulate residual stress in hybrid-AM components and to examine the sensitivity of RUS measurements in terms of frequency shifts and mode shapes with respect to single hybrid layers. Then, the RUS results are used to predict stress for a layer at a known location with unknown stress. Here, the approach highlights the capabilities of RUS to address an AM characterization challenge.
36 MATERIALS SCIENCE↗
Optimization of residual stresses in MMC's through the variation of interfacial layer architectures and processing parameters
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.
Pindera, Marek-Jerzy↗
MODELS FOR ESTIMATING THE AUTOFRETTAGE PRESSURE AND RESIDUAL STRESSES IN WALLS OF TYPE 2 PRESSURE VESSELS
Autofrettage is a manufacturing process used during fabrication of Type 2 pressure vessels designed for usage at high pressures to enhance the fatigue life. The process locks high compressive residual stresses in the vessel’s liner wall that reduce the maximum and the mean stress during service loading. To achieve a consistent residual stress profile across the wall of the vessel, the choice of autofrettage pressure is critical. Several finite element analyses runs were conducted to estimate the correct autofrettage pressure that is a function of the yield strength of the liner material, the wall thickness, and the outside diameter of the liner for a wrap thickness of 17.06 mm (48 wire layers). From the finite element analyses results, models were developed to estimate the correct autofrettage pressure and the residual stress distribution across the liner wall as a function of the yield strength of the liner material, the wall thickness, and the outside diameter of the liner.
08 HYDROGEN↗
Residual stress evaluation of components produced via direct metal laser sintering
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 element 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.
36 MATERIALS SCIENCE↗