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Sample records for high residual stresses

  1. Residual stress in a thick section high strength T-butt weld

    International Nuclear Information System (INIS)

    Pearce, S.V.; Linton, V.M.; Oliver, E.C.

    2008-01-01

    Residual stresses in a structure are generated as a result of the various fabrication and welding processes used to make the component. Being able to quantify these residual stresses is a key step in determining the continuing integrity of a structure in service. In this work, the residual stresses around a high strength, quenched and tempered steel T-butt web to curved plate weld have been measured using neutron strain scanning. The results show that the residual stresses near the weld were dominated by the welding residual stresses, while the stresses further from the weld were dominated by the bending residual stresses. The results suggest that the combination of welding-induced residual stress and significant pre-welding residual stress, as in the case of a thick bent section of plate can significantly alter the residual stress profile from that in a flat plate

  2. Residual stress by repair welds

    International Nuclear Information System (INIS)

    Mochizuki, Masahito; Toyoda, Masao

    2003-01-01

    Residual stress by repair welds is computed using the thermal elastic-plastic analysis with phase-transformation effect. Coupling phenomena of temperature, microstructure, and stress-strain fields are simulated in the finite-element analysis. Weld bond of a plate butt-welded joint is gouged and then deposited by weld metal in repair process. Heat source is synchronously moved with the deposition of the finite-element as the weld deposition. Microstructure is considered by using CCT diagram and the transformation behavior in the repair weld is also simulated. The effects of initial stress, heat input, and weld length on residual stress distribution are studied from the organic results of numerical analysis. Initial residual stress before repair weld has no influence on the residual stress after repair treatment near weld metal, because the initial stress near weld metal releases due to high temperature of repair weld and then stress by repair weld regenerates. Heat input has an effect for residual stress distribution, for not its magnitude but distribution zone. Weld length should be considered reducing the magnitude of residual stress in the edge of weld bead; short bead induces high tensile residual stress. (author)

  3. Residual stresses

    International Nuclear Information System (INIS)

    Sahotra, I.M.

    2006-01-01

    The principal effect of unloading a material strained into the plastic range is to create a permanent set (plastic deformation), which if restricted somehow, gives rise to a system of self-balancing within the same member or reaction balanced by other members of the structure., known as residual stresses. These stresses stay there as locked-in stresses, in the body or a part of it in the absence of any external loading. Residual stresses are induced during hot-rolling and welding differential cooling, cold-forming and extruding: cold straightening and spot heating, fabrication and forced fitting of components constraining the structure to a particular geometry. The areas which cool more quickly develop residual compressive stresses, while the slower cooling areas develop residual tensile stresses, and a self-balancing or reaction balanced system of residual stresses is formed. The phenomenon of residual stresses is the most challenging in its application in surface modification techniques determining endurance mechanism against fracture and fatigue failures. This paper discusses the mechanism of residual stresses, that how the residual stresses are fanned and what their behavior is under the action of external forces. Such as in the case of a circular bar under limit torque, rectangular beam under limt moment, reclaiming of shafts welds and peening etc. (author)

  4. Residual stresses

    International Nuclear Information System (INIS)

    Macherauch, E.

    1978-01-01

    Residual stresses are stresses which exist in a material without the influence of external powers and moments. They come into existence when the volume of a material constantly changes its form as a consequence of mechanical, thermal, and/or chemical processes and is hindered by neighbouring volumes. Bodies with residual stress are in mechanical balance. These residual stresses can be manifested by means of all mechanical interventions disturbing this balance. Acoustical, optical, radiological, and magnetical methods involving material changes caused by residual stress can also serve for determining residual stress. Residual stresses have an ambivalent character. In technical practice, they are feared and liked at the same time. They cause trouble because they can be the cause for unexpected behaviour of construction elements. They are feared since they can cause failure, in the worst case with catastrophical consequences. They are appreciated, on the other hand, because, in many cases, they can contribute to improvements of the material behaviour under certain circumstances. But they are especially liked for their giving convenient and (this is most important) mostly uncontrollable explanations. For only in very few cases we have enough knowledge and possibilities for the objective evaluation of residual stresses. (orig.) [de

  5. Analysis of the Residual Stresses in Helical Cylindrical Springs at High Temperature

    Directory of Open Access Journals (Sweden)

    H. Sun

    2015-01-01

    Full Text Available Creep is one of the basic properties of materials, its speed significantly depends on the temperature. Helical cylindrical springs are widely used in the elements of heating systems. This results in necessity of taking into account the effect of temperature on the stress-strain state of the spring. The object of research is a helical cylindrical spring used at high temperatures. Under this condition the spring state stability should be ensured.The paper studies relaxation of stress state and generation of residual stresses. Calculations are carried out in ABAQUS environment. The purpose of this work is to discuss the law of relaxation and residual stress in the spring.This paper describes the basic creep theories of helical cylindrical spring material. The calculation formulas of shear stress relaxation for a fixed compression ratio are obtained. Distribution and character of stress contour lines in the cross section of spring are presented. The stress relaxation – time relationships are discussed. The approximate formula for calculating relaxation shear stresses in the cross section of helical springs is obtained.The paper investigates creep ratio and law of residual stress variation in the cross-section of spring at 650℃. Computer simulation in ABAQUS environment was used. Research presents a finite element model of the spring creep in the cross-section.The paper conducts analysis of the stress changes for the creep under constant load. Under constant load stresses are quickly decreased in the around area of cross-section and are increased in the centre, i.e. the maximum and minimum stresses come close with time. Research work shows the possibility for using the approximate formula to calculate the relaxation shear stress in the cross section of spring and can provide a theoretical basis for predicting the service life of spring at high temperatures.In research relaxation processes of stress state are studied. Finite element model is cre

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

    International Nuclear Information System (INIS)

    Desmaison, Olivier; Mocellin, Katia; Jardin, Nicolas

    2011-01-01

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

  7. Optimization of Residual Stress of High Temperature Treatment Using Genetic Algorithm and Neural Network

    Directory of Open Access Journals (Sweden)

    M. Susmikanti

    2015-12-01

    Full Text Available In a nuclear industry area, high temperature treatment of materials is a factor which requires special attention. Assessment needs to be conducted on the properties of the materials used, including the strength of the materials. The measurement of material properties under thermal processes may reflect residual stresses. The use of Genetic Algorithm (GA to determine the optimal residual stress is one way to determine the strength of a material. In residual stress modeling with several parameters, it is sometimes difficult to solve for the optimal value through analytical or numerical calculations. Here, GA is an efficient algorithm which can generate the optimal values, both minima and maxima. The purposes of this research are to obtain the optimization of variable in residual stress models using GA and to predict the center of residual stress distribution, using fuzzy neural network (FNN while the artificial neural network (ANN used for modeling. In this work a single-material 316/316L stainless steel bar is modeled. The minimal residual stresses of the material at high temperatures were obtained with GA and analytical calculations. At a temperature of 6500C, the GA optimal residual stress estimation converged at –711.3689 MPa at adistance of 0.002934 mm from center point, whereas the analytical calculation result at that temperature and position is -975.556 MPa . At a temperature of 8500C, the GA result was -969.868 MPa at 0.002757 mm from the center point, while with analytical result was -1061.13 MPa. The difference in residual stress between GA and analytical results at a temperatureof6500C is about 27 %, while at 8500C it is 8.67 %. The distribution of residual stress showed a grouping concentrated around a coordinate of (-76; 76 MPa. The residuals stress model is a degree-two polynomial with coefficients of 50.33, -76.54, and -55.2, respectively, with a standard deviation of 7.874.

  8. Residual stresses around Vickers indents

    International Nuclear Information System (INIS)

    Pajares, A.; Guiberteau, F.; Steinbrech, R.W.

    1995-01-01

    The residual stresses generated by Vickers indentation in brittle materials and their changes due to annealing and surface removal were studied in 4 mol% yttria partially stabilized zirconia (4Y-PSZ). Three experimental methods to gain information about the residual stress field were applied: (i) crack profile measurements based on serial sectioning, (ii) controlled crack propagation in post indentation bending tests and (iii) double indentation tests with smaller secondary indents located around a larger primary impression. Three zones of different residual stress behavior are deduced from the experiments. Beneath the impression a crack free spherical zone of high hydrostatic stresses exists. This core zone is followed by a transition regime where indentation cracks develop but still experience hydrostatic stresses. Finally, in an outward third zone, the crack contour is entirely governed by the tensile residual stress intensity (elastically deformed region). Annealing and surface removal reduce this crack driving stress intensity. The specific changes of the residual stresses due to the post indentation treatments are described and discussed in detail for the three zones

  9. Residual-stress distributions near stainless steel butt weldments

    International Nuclear Information System (INIS)

    Elligson, W.A.; Shack, W.J.

    1978-01-01

    Concern for the integrity of stainless steel butt-weldments in boiling-water-reactor (BWR) piping systems has stimulated study of the conditions that cause stress corrosion cracking (SCC) in the heat-affected zones (HAZ) of the weldments. It is generally agreed that a high stress exceeding the initial yield strength is one of the essential elements for crack initiation. Since design procedures usually ensure that load stresses are below initial yield, the source of the high stresses necessary to produce SCC is thought to be the residual stresses due to welding. To examine the level of residual stresses in the weldments of interest, bulk residual stresses were measured on 100 mm (4-in.) and 254 mm (10-in.) diameter Schedule 80 piping weldments using strain relief techniques. Both laboratory welded specimens and field welded specimens from reactors in service were studied. Axial bulk residual stress distributions were obtained at 45 0 intervals around the circumference. At each azimuthal position, the residual stresses were measured at seven axial positions: on the weld centerline and 13, 20, and 25 mm on either side of the weld centerline on both the inside and outside surfaces

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

    Science.gov (United States)

    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.

  11. Welding residual stress improvement in internal components by water jet peening

    International Nuclear Information System (INIS)

    Enomoto, K.; Hirano, K.; Hayashi, M.; Hayashi, E.

    1996-01-01

    Cavitations are generated when highly pressurized water is jetted in water. Surface residual stress is improved remarkably due to the peening effect of extremely high pressure caused by the collapse of cavitation bubbles. This technique is called water jet peening (WJP). WJP is expected to be an effective maintenance technique for the prevention of stress corrosion cracking caused by residual stress in various components of power generating plants. Various kinds of specimens were water jet peened to evaluate the fundamental characteristics of WJP and to select the most appropriate conditions for the residual stress improvement. Test results showed that WJP markedly improved the tensile residual stress caused by welding and grinding to the high compressive residual stress and seems to prevent the stress corrosion cracking

  12. Analysis of Metal Flow Behavior and Residual Stress Formation of Complex Functional Profiles under High-Speed Cold Roll-Beating

    Directory of Open Access Journals (Sweden)

    Fengkui Cui

    2018-01-01

    Full Text Available To obtain a good surface layer performance of the complex functional profile during the high-speed cold roll-beating forming process, this paper analyzed the metal plastic flow and residual stress-formed mechanism by using a theoretical model of the metal flow and residual stress generation. By using simulation software, the cold roll-beating forming process of a spline shaft was simulated and analyzed. The metal flow and residual stress formation law in the motion were researched. In a practical experiment, the changes in the grains in the spline tooth profile section and the residual stress distribution on the tooth profile were studied. A microcorrespondence relationship was established between the metal plastic flow and the residual stress generation. The conclusions indicate that the rate at which the metal flow decreases changes gradually at different metal layers. The residual stress value is directly related to the plastic flow difference. As the roll-beating speed increases, the uneven degree of plastic deformation at the workpiece surface increases, and the residual stress in the tooth profile is generally greater. At the same roll-beating speed, the rate change trend of the metal flow decreases gradually from the surface to the inner layer and from the dedendum to the addendum. The residual stress distribution on the surface of the tooth profile decreases from the dedendum to the addendum. These findings provide a basis and guidance for the controlled use of residual stress, obtaining better surface layer quality in the high-speed cold roll-beating process of the complex functional profile.

  13. Recent advances in residual stress measurement

    International Nuclear Information System (INIS)

    Withers, P.J.; Turski, M.; Edwards, L.; Bouchard, P.J.; Buttle, D.J.

    2008-01-01

    Until recently residual stresses have been included in structural integrity assessments of nuclear pressure vessels and piping in a very primitive manner due to the lack of reliable residual stress measurement or prediction tools. This situation is changing the capabilities of newly emerging destructive (i.e. the contour method) and non-destructive (i.e. magnetic and high-energy synchrotron X-ray strain mapping) residual stress measurement techniques for evaluating ferritic and austenitic pressure vessel components are contrasted against more well-established methods. These new approaches offer the potential for obtaining area maps of residual stress or strain in welded plants, mock-up components or generic test-pieces. The mapped field may be used directly in structural integrity calculations, or indirectly to validate finite element process/structural models on which safety cases for pressurised nuclear systems are founded. These measurement methods are complementary in terms of application to actual plant, cost effectiveness and measurements in thick sections. In each case an exemplar case study is used to illustrate the method and to highlight its particular capabilities

  14. Residual stress concerns in containment analysis

    International Nuclear Information System (INIS)

    Costantini, F.; Kulak, R. F.; Pfeiffer, P. A.

    1997-01-01

    The manufacturing of steel containment vessels starts with the forming of flat plates into curved plates. A steel containment structure is made by welding individual plates together to form the sections that make up the complex shaped vessels. The metal forming and welding process leaves residual stresses in the vessel walls. Generally, the effect of metal forming residual stresses can be reduced or virtually eliminated by thermally stress relieving the vesseL In large containment vessels this may not be practical and thus the residual stresses due to manufacturing may become important. The residual stresses could possibly tiect the response of the vessel to internal pressurization. When the level of residual stresses is significant it will affect the vessel's response, for instance the yielding pressure and possibly the failure pressure. The paper will address the effect of metal forming residual stresses on the response of a generic pressure vessel to internal pressurization. A scoping analysis investigated the effect of residual forming stresses on the response of an internally pressurized vessel. A simple model was developed to gain understanding of the mechanics of the problem. Residual stresses due to the welding process were not considered in this investigation

  15. Residual stresses in weld-clad reactor pressure vessel steel

    International Nuclear Information System (INIS)

    Bertram, W.

    1975-01-01

    Cladding of low alloy nuclear reactor pressure vessel steel with austenitic stainless steel introduces in heavy section components high residual stresses which may cause microcrack formation in stress relief heat treatment. In this investigation an attempt is made to contribute to the solution of the stress relief cracking problem by determining quantitatively the magnitude and distribution of the residual stresses after cladding and after subsequent stress relief heat treatment. The distribution of residual stresses was determined on the basis of a combined experimental-mathematical procedure. Heavy section plate specimens of low alloy steel as base material were given an austenitic monolayer-cladding using the techniques of strip electrode and plasma hot wire cladding, respectively. A number of plates was stress relief heat treated. Starting from the cladded surface the thickness of the plates was reduced by subsequent removal of layers of material. The elastic strain reaction to the removal of each layer was measured by strain gauges. From the data obtained the biaxial residual stress distribution was computed as a function of thickness using relations which are derived for this particular case. In summary, lower residual stresses are caused by reduced thickness of the components. As the heat input, is decreased at identical base material thickness, the residual stresses are lowered also. The height of the tensile residual stress peak, however, remains approximataly constant. In stress relief annealed condition the residual stresses in the cladding are in tension; in the base material the residual stresses are negligibly small

  16. Residual stresses and stress corrosion cracking in pipe fittings

    International Nuclear Information System (INIS)

    Parrington, R.J.; Scott, J.J.; Torres, F.

    1994-06-01

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

  17. Behavior of surface residual stress in explosion hardened high manganese austenitic cast steel due to repeated impact loads

    International Nuclear Information System (INIS)

    Oda, Akira; Miyagawa, Hideaki

    1985-01-01

    Explosion hardened high manganese austenitic cast steel is being tried for rail crossing recently. From the previous studies, it became clear that high tensile residual stress was generated in the hardened surface layer by explosion and microcracks were observed. In this study, therefore, the behavior of surface residual stress in explosion hardened steel due to repeated impact loads was examined and compared with those of the original and shot peened steels. The results obtained are summarized as follows: (1) In the initial stage of the repetition of impact, high tensile surface residual stress in explosion hardened steel decreased rapidly with the repetition of impact, while those of the original and shot peened steels increased rapidly. This difference was attributed to the difference in depth of the work hardened layer in three testing materials. (2) Beyond 20 impacts the residual stress of three test specimens decreased gradually, and at more than 2000 impacts the compressive stress of about 500 MPa was produced regardless of the histories of working of testing materials. (3) The linear law in the second stage of residual stress fading was applicable to this case, and the range of the linear relationship was related to the depth of the work hardened layer of testing material. (4) From the changes in half-value breadth and peak intensity of diffraction X-ray, it was supposed that a peculiar microscopic strain exists in explosion hardened steel. (author)

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

    Science.gov (United States)

    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.

  19. Controlling BWR pipe cracking by residual stress modification

    International Nuclear Information System (INIS)

    Gilman, J.D.; Giannuzzi, A.J.; Childs, W.J.

    1983-01-01

    Intergranular stress corrosion cracking may occur in the weld heat-affected zone of susceptible stainless steel materials which have been used in some boiling water reactor piping systems. One of the prerequisite conditions for stress corrosion attack is a high tensile stress in the exposed, locally sensitized material near the weld root. Several processes have been developed which can deter stress corrosion attack by altering the residual stress distributions near the welds to ensure that low stresses prevail in critical locations. These residual stress modification remedies and their qualification testing are described in this paper. (author)

  20. Residual stress measurement with focused acoustic waves and direct comparison with X-ray diffraction stress measurements

    International Nuclear Information System (INIS)

    Sathish, Shamachary; Moran, Thomas J.; Martin, Richard W.; Reibel, Richard

    2005-01-01

    The technique of measuring small changes in acoustic wave velocity due to external or internal stress has been used for quantitative determination of residual stress in materials during the last decade. Application of similar methodology with focused acoustic waves leads to residual stress measurement with spatial resolution of a few millimeters to a few microns. The high spatial resolution residual stress measurement required development of new methodologies in both the design of acoustic lenses and the instrumentation for acoustic wave velocity determination. This paper presents two new methodologies developed for the measurement of residual stress with spatial resolution of a few millimeters. The design of new type of acoustic lens for achieving higher spatial resolution in residual stress measurement is introduced. Development of instrumentation for high precision local surface wave velocity measurement will be presented. Residual stresses measured around a crack tip in a sample of Ti-6A1-4V using a focused beam will be compared with X-ray diffraction measurements performed on the same region of the sample. Results of residual stress measurements along a direction perpendicular to the electron beam weld in a sample of Ti-6A1-4V, determined using focused acoustic waves and X-ray diffraction technique, are also presented. The spatial resolution and penetration depth of X-rays and focused acoustic beams with reference to residual stress measurements are discussed

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

    Energy Technology Data Exchange (ETDEWEB)

    Stegemann, Robert, E-mail: Robert.Stegemann@bam.de [Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12200 Berlin (Germany); Cabeza, Sandra; Lyamkin, Viktor; Bruno, Giovanni; Pittner, Andreas [Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12200 Berlin (Germany); Wimpory, Robert; Boin, Mirko [HZB Helmholtz-Zentrum Berlin, Hahn-Meitner-Platz 1, 14109 Berlin (Germany); Kreutzbruck, Marc [Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12200 Berlin (Germany); IKT, University of Stuttgart, Pfaffenwaldring 32, 70569 Stuttgart (Germany)

    2017-03-15

    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. - Highlights: • Comparison of magnetic microstructure with neutron diffraction stress analysis. • High spatial resolution magnetic stray field images of hypereutectoid TIG welds. • Spatial variations of the stray fields are below the magnetic field of the earth. • GMR spin valve gradiometer arrays adapted for the evaluation of magnetic microstructures. • Magnetic stray fields are closely linked to microstructure of the material.

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

    Science.gov (United States)

    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.

  3. Residual Stress Testing of Outer 3013 Containers

    International Nuclear Information System (INIS)

    Dunn, K.

    2004-01-01

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

  4. High energy x-ray synchrotron radiation analysis of residual stress distribution of shot-peened steels

    International Nuclear Information System (INIS)

    Tanaka, Keisuke; Akiniwa, Yoshiaki; Kimachi, Hirohisa; Suzuki, Kenji; Yanase, Etsuya; Nishio, Kouji; Kusumi, Yukihiro

    2001-01-01

    A high energy X-ray beam from synchrotron radiation source SPring-8 was used to determine the residual stress distribution beneath the shot-peened surface of carbon steel plates. By using the monochromatic X-ray beam with an energy of 72 keV, the relation between 2θ and sin 2 ψ was obtained by the side-inclination method upto sin 2 ψ = 0.9. The distribution of the residual stress was determined from the non-linearity of the relation between 2θ and sin 2 ψ. (author)

  5. Neutron residual stress measurements in linepipe

    International Nuclear Information System (INIS)

    Law, Michael; Gnaepel-Herold, Thomas; Luzin, Vladimir; Bowie, Graham

    2006-01-01

    Residual stresses in gas pipelines are generated by manufacturing and construction processes and may affect the subsequent pipe integrity. In the present work, the residual stresses in eight samples of linepipe were measured by neutron diffraction. Residual stresses changed with some coating processes. This has special implications in understanding and mitigating stress corrosion cracking, a major safety and economic problem in some gas pipelines

  6. Residual-stress measurements

    Energy Technology Data Exchange (ETDEWEB)

    Ezeilo, A N; Webster, G A [Imperial College, London (United Kingdom); Webster, P J [Salford Univ. (United Kingdom)

    1997-04-01

    Because neutrons can penetrate distances of up to 50 mm in most engineering materials, this makes them unique for establishing residual-stress distributions non-destructively. D1A is particularly suited for through-surface measurements as it does not suffer from instrumental surface aberrations commonly found on multidetector instruments, while D20 is best for fast internal-strain scanning. Two examples for residual-stress measurements in a shot-peened material, and in a weld are presented to demonstrate the attractive features of both instruments. (author).

  7. X-ray study of residual stress distribution of ground ceramics

    International Nuclear Information System (INIS)

    Sakaida, Yoshihisa; Tanaka, Keisuke; Ikuhara, Yuichi; Suzuki, Kenzi.

    1997-01-01

    The residual stress distribution of ground ceramics was determined from the eigen strain existing in the ground surface. The eigen strain of ground ceramics was tensile, and exponentially decreased with the distance from the surface. The residual stress distribution is given as a superposition of an exponential function of compression and a linear function. It is found that the actual residual stress distribution can be approximated by a compressive exponential function because the magnitude of tensile residual stress is negligibly small compared to the compressive residual stress. In the experiments, the diffraction angle was measured on ground silicon nitride for a wide range of sin 2 ψ using the glancing incidence X-ray diffraction technique. A strong nonlinearity was found in the 2θ-sin 2 ψ diagram at very high ψ-angles. From the analysis of nonlinearity, the residual stress distribution was determined. The residual stress distribution of silicon nitride coincided with the distribution calculated from the eigen strain distribution. Transmission electron microscopy was used to clarify the origin of generation of the residual stress. Both strain contrasts and microcracks were observed below the ground surface ; straight dislocations were also observed within silicon nitride grains near the ground surface. (author)

  8. Evaluation of residual stress in sputtered tantalum thin-film

    Energy Technology Data Exchange (ETDEWEB)

    Al-masha’al, Asa’ad, E-mail: asaad.al@ed.ac.uk; Bunting, Andrew; Cheung, Rebecca

    2016-05-15

    Highlights: • Tantalum thin-films have been deposited by DC magnetron sputtering system. • Thin-film stress is observed to be strongly influenced by sputtering pressure. • Transition towards the compressive stress is ascribed to the annealing at 300 °C. • Expose thin-film to air ambient or ion bombardment lead to a noticeable change in the residual stress. - Abstract: The influence of deposition conditions on the residual stress of sputtered tantalum thin-film has been evaluated in the present study. Films have been deposited by DC magnetron sputtering and curvature measurement method has been employed to calculate the residual stress of the films. Transitions of tantalum film stress from compressive to tensile state have been observed as the sputtering pressure increases. Also, the effect of annealing process at temperature range of 90–300 °C in oxygen ambient on the residual stress of the films has been studied. The results demonstrate that the residual stress of the films that have been deposited at lower sputtering pressure has become more compressive when annealed at 300 °C. Furthermore, the impact of exposure to atmospheric ambient on the tantalum film stress has been investigated by monitoring the variation of the residual stress of both annealed and unannealed films over time. The as-deposited films have been exposed to pure Argon energy bombardment and as result, a high compressive stress has been developed in the films.

  9. Measurements of three dimensional residual stress distribution on laser irradiated spot

    International Nuclear Information System (INIS)

    Tanaka, Hirotomo; Akita, Koichi; Ohya, Shin-ichi; Sano, Yuji; Naito, Hideki

    2004-01-01

    Three dimensional residual stress distributions on laser irradiated spots were measured using synchrotron radiation to study the basic mechanism of laser peening. A water-immersed sample of high tensile strength steel was irradiated with Q-switched and frequency-doubled Nd:YAG laser. The residual stress depth profile of the sample was obtained by alternately repeating the measurement and surface layer removal by electrolytic polishing. Tensile residual stresses were observed on the surface of all irradiated spots, whereas residual stress changed to compressive just beneath the surface. The depth of compressive residual stress imparted by laser irradiation and plastic deformation zone increased with increasing the number of laser pulses irradiated on the same spot. (author)

  10. Development of residual stress prediction model in pipe weldment

    Energy Technology Data Exchange (ETDEWEB)

    Eom, Yun Yong; Lim, Se Young; Choi, Kang Hyeuk; Cho, Young Sam; Lim, Jae Hyuk [Korea Advanced Institute of Science and Technology, Taejon (Korea, Republic of)

    2002-03-15

    When Leak Before Break(LBB) concepts is applied to high energy piping of nuclear power plants, residual weld stresses is a important variable. The main purpose of his research is to develop the numerical model which can predict residual weld stresses. Firstly, basic theories were described which need to numerical analysis of welding parts. Before the analysis of pipe, welding of a flat plate was analyzed and compared. Appling the data of used pipes, thermal/mechanical analysis were accomplished and computed temperature gradient and residual stress distribution. For thermal analysis, proper heat flux was regarded as the heat source and convection/radiation heat transfer were considered at surfaces. The residual stresses were counted from the computed temperature gradient and they were compared and verified with a result of another research.

  11. Effect of applied stress on the compressive residual stress introduced by laser peening

    International Nuclear Information System (INIS)

    Sumiya, Rie; Tazawa, Toshiyuki; Narazaki, Chihiro; Saito, Toshiyuki; Kishimoto, Kikuo

    2016-01-01

    Peening is the process which is able to be generated compressive residual stress and is known to be effective for preventing SCC initiation and improvement of fatigue strength. Laser peening is used for the nuclear power plant components in order to prevent SCC initiation. Although it is reported that the compressive residual stress decreases due to applied stresses under general operating condition, the change of residual stress might be large under excessive loading such as an earthquake. The objectives of this study are to evaluate the relaxation behavior of the compressive residual stress due to laser peening and to confirm the surface residual stress after loading. Therefore laser peened round bar test specimens of SUS316L which is used for the reactor internals of nuclear power plant were loaded at room temperature and elevated temperature and then surface residual stresses were measured by X-ray diffraction method. In the results of this test, it was confirmed that the compressive residual stress remained after applying uniform stress larger than 0.2% proof stress, and the effect of cyclic loading on the residual stress was small. The effect of applying compressive stress on the residual stress relaxation was confirmed to be less than that of applying tensile stress. Plastic deformation through a whole cross section causes the change in the residual stress distribution. As a result, the surface compressive residual stress is released. It was shown that the effect of specimen size on residual stress relaxation and the residual stress relaxation behavior in the stress concentration region can be explained by assumed stress relaxation mechanism. (author)

  12. INTERFACE RESIDUAL STRESSES IN DENTAL ZIRCONIA USING LAUE MICRO-DIFFRACTION

    International Nuclear Information System (INIS)

    Bale, H. A.; Tamura, N.; Coelho, P.G.; Hanan, J. C.

    2009-01-01

    Due to their aesthetic value and high compressive strength, dentists have recently employed ceramics for restoration materials. Among the ceramic materials, zirconia provides high toughness and crack resistant characteristics. Residual stresses develop in processing due to factors including grain anisotropy and thermal coefficient mismatch. In the present study, polychromatic X-ray (Laue) micro-diffraction provided grain orientation and residual stresses on a clinically relevant zirconia model ceramic disk. A 0.5 mm x 0.024 mm region on zirconia was examined on a 500 nm scale for residual stresses using a focused poly-chromatic synchrotron X-ray beam. Large stresses ranging from - to + 1GPa were observed at some grains. On average, the method suggests a relatively small compressive stress at the surface between 47 and 75 MPa depending on direction

  13. Relation Between Residual and Hoop Stresses and Rolling Bearing Fatigue Life

    Science.gov (United States)

    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.

  14. Residual stress improving method for reactor structural component and residual stress improving device therefor

    Energy Technology Data Exchange (ETDEWEB)

    Enomoto, Kunio; Otaka, Masahiro; Kurosawa, Koichi; Saito, Hideyo; Tsujimura, Hiroshi; Tamai, Yasukata; Urashiro, Keiichi; Mochizuki, Masato

    1996-09-03

    The present invention is applied to a BWR type reactor, in which a high speed jetting flow incorporating cavities is collided against the surface of reactor structural components to form residual compression stresses on the surface layer of the reactor structural components thereby improving the stresses on the surface. Namely, a water jetting means is inserted into the reactor container filled with reactor water. Purified water is pressurized by a pump and introduced to the water jetting means. The purified water jetted from the water jetting means and entraining cavities is abutted against the surface of the reactor structural components. With such procedures, since the purified water is introduced to the water jetting means by the pump, the pump is free from contamination of radioactive materials. As a result, maintenance and inspection for the pump can be facilitated. Further, since the purified water injection flow entraining cavities is abutted against the surface of the reactor structural components being in contact with reactor water, residual compression stresses are exerted on the surface of the reactor structural components. As a result, occurrence of stress corrosion crackings of reactor structural components is suppressed. (I.S.)

  15. Residual stress improving method for reactor structural component and residual stress improving device therefor

    International Nuclear Information System (INIS)

    Enomoto, Kunio; Otaka, Masahiro; Kurosawa, Koichi; Saito, Hideyo; Tsujimura, Hiroshi; Tamai, Yasukata; Urashiro, Keiichi; Mochizuki, Masato.

    1996-01-01

    The present invention is applied to a BWR type reactor, in which a high speed jetting flow incorporating cavities is collided against the surface of reactor structural components to form residual compression stresses on the surface layer of the reactor structural components thereby improving the stresses on the surface. Namely, a water jetting means is inserted into the reactor container filled with reactor water. Purified water is pressurized by a pump and introduced to the water jetting means. The purified water jetted from the water jetting means and entraining cavities is abutted against the surface of the reactor structural components. With such procedures, since the purified water is introduced to the water jetting means by the pump, the pump is free from contamination of radioactive materials. As a result, maintenance and inspection for the pump can be facilitated. Further, since the purified water injection flow entraining cavities is abutted against the surface of the reactor structural components being in contact with reactor water, residual compression stresses are exerted on the surface of the reactor structural components. As a result, occurrence of stress corrosion crackings of reactor structural components is suppressed. (I.S.)

  16. Prediction of residual stress distributions due to surface machining and welding and crack growth simulation under residual stress distribution

    International Nuclear Information System (INIS)

    Ihara, Ryohei; Katsuyama, JInya; Onizawa, Kunio; Hashimoto, Tadafumi; Mikami, Yoshiki; Mochizuki, Masahito

    2011-01-01

    Research highlights: → Residual stress distributions due to welding and machining are evaluated by XRD and FEM. → Residual stress due to machining shows higher tensile stress than welding near the surface. → Crack growth analysis is performed using calculated residual stress. → Crack growth result is affected machining rather than welding. → Machining is an important factor for crack growth. - Abstract: In nuclear power plants, stress corrosion cracking (SCC) has been observed near the weld zone of the core shroud and primary loop recirculation (PLR) pipes made of low-carbon austenitic stainless steel Type 316L. The joining process of pipes usually includes surface machining and welding. Both processes induce residual stresses, and residual stresses are thus important factors in the occurrence and propagation of SCC. In this study, the finite element method (FEM) was used to estimate residual stress distributions generated by butt welding and surface machining. The thermoelastic-plastic analysis was performed for the welding simulation, and the thermo-mechanical coupled analysis based on the Johnson-Cook material model was performed for the surface machining simulation. In addition, a crack growth analysis based on the stress intensity factor (SIF) calculation was performed using the calculated residual stress distributions that are generated by welding and surface machining. The surface machining analysis showed that tensile residual stress due to surface machining only exists approximately 0.2 mm from the machined surface, and the surface residual stress increases with cutting speed. The crack growth analysis showed that the crack depth is affected by both surface machining and welding, and the crack length is more affected by surface machining than by welding.

  17. Relation between psi-splitting and microscopic residual shear stresses in x-ray stress measurement on uni-directionally deformed layers

    International Nuclear Information System (INIS)

    Hanabusa, Takao; Fujiwara, Haruo

    1982-01-01

    The psi-splitting behaviors were investigated for the ground and the milled surface layers of both iron and high speed steel in order to find out the relation among microscopic residual shear stresses. For the high speed steel, the X-ray elastic constants and the residual strains were measured on the carbide phase as well as on the matrix phase. It was clarified that the psi-splitting was caused by a combination of the selective nature of X-ray diffractions and the microscopic residual shear stresses within the interior of cells and the carbide particles. The volume fraction occupied by the cell walls and the residual shear stresses sustained by them were estimated from the equilibrium condition of the microscopic residual shear stresses. The distributions of residual stresses over the deformed layers indicate that the thermal effect is dominant in grinding and the mechanical effect is dominant in milling for forming residual stresses. (author)

  18. Consideration of microstructure evolution and residual stress measurement near severe worked surface using high energy x-ray

    International Nuclear Information System (INIS)

    Hashimoto, Tadafumi; Mochizuki, Masahito; Shobu, Takahisa

    2012-01-01

    It is necessary to establish a measurement method that can evaluate accurate stress on the surface. However, the microstructure evolution takes place near the surface due to severe plastic deformation, since structural members have been superpositioned a lot of working processes to complete. As well known, a plane stress can't be assumed on the severe worked surface. Therefore we have been proposed the measurement method that can be measured the in-depth distribution of residual stress components by using high energy X-ray from a synchrotron radiation source. There is the combination of the constant penetration depth method and tri-axial stress analysis. Measurements were performed by diffraction planes for the orientation parameter Γ=0.25 of which elastic constants are nearly equal to the mechanical one. The stress components obtained must be converted to the stress components in real space by using optimization technique, since it corresponds to the weighted average stress components associated with the attenuation of X-ray in materials. The predicted stress components distribution agrees very well with the corrected one which was measured by the conventional removal method. To verify the availability of the proposed method, thermal aging variation of residual stress components on the severe worked surface under elevated temperature was investigated using specimen superpositioned working processes (i.e., welding, machining, peening). It is clarified that the residual stress components increase with thermal aging, using the diffraction planes in hard elastic constants to the bulk. This result suggests that the thermal stability of residual stress has the dependence of the diffraction plane. (author)

  19. Neutron diffraction measurement of residual stress in NPP construction materials

    International Nuclear Information System (INIS)

    Hinca, R.; Bokuchava, G.

    2000-01-01

    The aim of the investigation is to study the level of residual stresses induced by the surfacing in the weld deposit zone and in the base metal, where considerable thermal gradients are present. Surfacing high-nickel filler on an austenitic base metal is one of techniques in repair of primary collector the primary circuit of nuclear power plant type VVER. The repair technology was developed at Welding Research Institute Bratislava. Measurements of residual stresses in the weld overlay and the base metal are necessary for approving the mechanical analysis and verifying of residual stresses determination on welded material by numerical weld g computer simulation. Investigations of residual stresses are important for developing optimal welding techniques. (authors)

  20. Mapping residual stresses in PbWO4 crystals using photo-elastic analysis

    International Nuclear Information System (INIS)

    Lebeau, M.; Gobbi, L.; Majni, G.; Paone, N.; Pietroni, P.; Rinaldi, D.

    2005-01-01

    Large scintillating crystals are affected by internal stresses induced by the crystal growth temperature gradient remanence. Cutting boules (ingots) into finished crystal shapes allows for a partial tension relaxation but residual stresses remain the main cause of breaking. Quality control of residual stresses is essential in the application of Scintillating Crystals to high-energy physics calorimeters (e.g. CMS ECAL at CERN LHC). In this context the industrial process optimisation towards stress reduction is mandatory. We propose a fast technique for testing samples during the production process in order to evaluate the residual stress distribution after the first phases of mechanical processing. We mapped the stress distribution in PbWO 4 slabs cut from the same production boule. The analysis technique is based on the stress intensity determination using the photo-elastic properties of the samples. The stress distribution is mapped in each sample. The analysis shows that there are regions of high residual tension close to the seed position and at the boule periphery. These results should allow for adapting the industrial process to producing crystals with lower residual stresses

  1. Prediction of residual stress using explicit finite element method

    Directory of Open Access Journals (Sweden)

    W.A. Siswanto

    2015-12-01

    Full Text Available This paper presents the residual stress behaviour under various values of friction coefficients and scratching displacement amplitudes. The investigation is based on numerical solution using explicit finite element method in quasi-static condition. Two different aeroengine materials, i.e. Super CMV (Cr-Mo-V and Titanium alloys (Ti-6Al-4V, are examined. The usage of FEM analysis in plate under normal contact is validated with Hertzian theoretical solution in terms of contact pressure distributions. The residual stress distributions along with normal and shear stresses on elastic and plastic regimes of the materials are studied for a simple cylinder-on-flat contact configuration model subjected to normal loading, scratching and followed by unloading. The investigated friction coefficients are 0.3, 0.6 and 0.9, while scratching displacement amplitudes are 0.05 mm, 0.10 mm and 0.20 mm respectively. It is found that friction coefficient of 0.6 results in higher residual stress for both materials. Meanwhile, the predicted residual stress is proportional to the scratching displacement amplitude, higher displacement amplitude, resulting in higher residual stress. It is found that less residual stress is predicted on Super CMV material compared to Ti-6Al-4V material because of its high yield stress and ultimate strength. Super CMV material with friction coefficient of 0.3 and scratching displacement amplitude of 0.10 mm is recommended to be used in contact engineering applications due to its minimum possibility of fatigue.

  2. Simplified method of calculating residual stress in circumferential welding of piping

    International Nuclear Information System (INIS)

    Umemoto, Tadahiro

    1984-01-01

    Many circumferential joints of piping are used in as-welded state, but in these welded joints, the residual stress as high as the yield stress of materials arises, and causes to accelerate stress corrosion cracking and corrosion fatigue. The experiment or the finite element method to clarify welding residual stress requires much time and labor, and is expensive, therefore, the author proposed the simplified method of calculation. The heating and cooling process of welding is very complex, and cannot be modeled as it is, therefore, it was assumed that in multiple layer welding, the welding condition of the last layer determines the residual stress, that material constants are invariable regardless of temperature, that the temperature distribution and residual stress are axisymmetric, and that there is repeated stress-strain relation in the vicinity of welded parts. The temperature distribution at the time of welding, thermal stress and welding residual stress are analyzed, and the material constants used for the calculation of residual stress are given. As the example of calculation, the effect of welding heat input and materials is shown. The extension of the method to a thick-walled pipe is discussed. (Kako, I.)

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

    Science.gov (United States)

    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.

  4. Modeling of CMUTs with Multiple Anisotropic Layers and Residual Stress

    DEFF Research Database (Denmark)

    Engholm, Mathias; Thomsen, Erik Vilain

    2014-01-01

    Usually the analytical approach for modeling CMUTs uses the single layer plate equation to obtain the deflection and does not take anisotropy and residual stress into account. A highly accurate model is developed for analytical characterization of CMUTs taking an arbitrary number of layers...... and residual stress into account. Based on the stress-strain relation of each layer and balancing stress resultants and bending moments, a general multilayered anisotropic plate equation is developed for plates with an arbitrary number of layers. The exact deflection profile is calculated for a circular...... clamped plate of anisotropic materials with residual bi-axial stress. From the deflection shape the critical stress for buckling is calculated and by using the Rayleigh-Ritz method the natural frequency is estimated....

  5. Basic numerical study on gap influence of residual stress and distortion during high-brightness laser butt welding

    International Nuclear Information System (INIS)

    Serizawa, Hisashi; Mori, Daiki; Murakawa, Hidekazu

    2013-01-01

    High-brightness laser such as fiber laser or disk laser is expected to minimize the total heat input energy in welding due to its high beam quality, and the welding residual stress and distortion also seem to be reduced as a result. However, the diameter of high-brightness laser beam is less than 0.6 mm and it is difficult to set the beam position to contact face between two parts because in general there would be a gap due to quality of parts. In this study, in order to reveal the effect of gap on the residual stress and the welding distortion during fiber laser welding, the butt welding of two plates were examined through the thermal elastic-plastic analysis with a new gap element. From the result of thermal analyses, it was found that the homogeneous ellipsoid body could be applicable to model the shape of heat source for the fiber laser and the gap width would not influence the penetration shape when the gap width was changed from 0.1 to 0.25 mm. In addition, the elastic-plastic analyses indicated that the transverse shrinkage slightly increased with increasing the gap width, while this shrinkage without gap was much smaller than that with gap. Also, it was revealed that the welding speed largely affects both the welding residual stress and distortion. Moreover, it was found that the residual stress was almost independent of the jig position, while the position of fixtures slightly affected the transverse shrinkage. (author)

  6. Residual stress analysis in BWR pressure vessel attachments

    International Nuclear Information System (INIS)

    Dexter, R.J.; Leung, C.P.; Pont, D.

    1992-06-01

    Residual stresses from welding processes can be the primary driving force for stress corrosion cracking (SCC) in BWR components. Thus, a better understanding of the causes and nature of these residual stresses can help assess and remedy SCC. Numerical welding simulation software, such as SYSWELD, and material property data have been used to quantify residual stresses for application to SCC assessments in BWR components. Furthermore, parametric studies using SYSWELD have revealed which variables significantly affect predicted residual stress. Overall, numerical modeling techniques can be used to evaluate residual stress for SCC assessments of BWR components and to identify and plan future SCC research

  7. Evaluation of stress intensity factors due to welding residual stresses for circumferential cracked pipes

    International Nuclear Information System (INIS)

    Oh, Chang-Young; Kim, Yun-Jae; Oh, Young-Jin; Kim, Jong-Sung; Song, Tae-Kwang; Kim, Yong-Beum

    2013-01-01

    To investigate the applicability of existing methods to estimate stress intensity factors due to welding residual stresses, comparisons with finite element (FE) solutions are made for two types of generic welding residual stress profiles, generated by simulating repair welds. It is found that fitting residual stresses over the crack depth using third-order polynomials gives good estimates of stress intensity factors but fitting over the entire thickness can result in inaccurate estimates even with fourth-order polynomials. Noting that welding residual stresses are often determined from FE analyses, linearization of residual stresses to estimate stress intensity factors is proposed. Comparison with FE solutions shows good agreements. -- Highlights: ► Applicability of K estimation methods is investigated for welding residual stresses. ► Two types of generic residual stress profiles with repair welds are considered. ► Fitting residual stresses over the crack depth gives good estimates of K. ► A method to estimate K by linearising residual stress profiles is proposed

  8. Residual stress in silicon wafer using IR polariscope

    Science.gov (United States)

    Lu, Zhijia; Wang, Pin; Asundi, Anand

    2008-09-01

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

  9. Measurement of residual stresses using fracture mechanics weight functions

    International Nuclear Information System (INIS)

    Fan, Y.

    2000-01-01

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

  10. Measurement of residual stresses using fracture mechanics weight functions

    International Nuclear Information System (INIS)

    Fan, Y.

    2001-01-01

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

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

    Science.gov (United States)

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

    1984-01-01

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

  12. Residual Stress Evaluation of Weld Inlay Process on Reactor Vessel Nozzles

    Energy Technology Data Exchange (ETDEWEB)

    Cho, Kihyun; Cho, Hong Seok [KEPCO KPS, Naju (Korea, Republic of)

    2015-10-15

    Weld overlay, weld inlay and stress improvement are mitigation technologies for butt joints. Weld overlay is done on pressurizer nozzles which are the highest potential locations occurring PWSCC due to high temperature in Korea. Reactor vessel nozzles are other big safety concerns for butt joints. Weld overlay and stress improvement should be so difficult to apply to those locations because space is too limited. Weld inlay should be one of the solutions. KEPCO KPS has developed laser welding system and process for reactor nozzles. Welding residual stress analysis is necessary for flaw evaluation. United States nuclear regulatory commission has calculated GTAW(Gas Tungsten Arc Welding) residual stress using ABAQUS. To confirm effectiveness of weld inlay process, welding residual stress analysis was performed. and difference between GTAW and LASER welding process was compared. Evaluation of weld inlay process using ANSYS and ABAQUS is performed. All of the both results are similar. The residual stress generated after weld inlay was on range of 450-500 MPa. Welding residual stresses are differently generated by GTAW and LASER welding. But regardless of welding process type, residual tensile stress is generated on inside surface.

  13. On Taylor-Series Approximations of Residual Stress

    Science.gov (United States)

    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.

  14. Sustainability of compressive residual stress by stress improvement processes

    International Nuclear Information System (INIS)

    Nishikawa, Satoru; Okita, Shigeru; Yamaguchi, Atsunori

    2013-01-01

    Stress improvement processes are countermeasures against stress corrosion cracking in nuclear power plant components. It is necessary to confirm whether compressive residual stress induced by stress improvement processes can be sustained under operation environment. In order to evaluate stability of the compressive residual stress in 60-year operating conditions, the 0.07% cyclic strains of 200 times at 593 K were applied to the welded specimens, then a thermal aging treatment for 1.66x10 6 s at 673 K was carried out. As the result, it was confirmed that the compressive residual stresses were sustained on both surfaces of the dissimilar welds of austenitic stainless steel (SUS316L) and nickel base alloy (NCF600 and alloy 182) processed by laser peening (LP), water jet peening (WJP), ultrasonic shot peening (USP), shot peening (SP) and polishing under 60-year operating conditions. (author)

  15. The effect of Residual Stress on the Stress Intensity Factor of Nuclear Material

    International Nuclear Information System (INIS)

    Song, Taek Ho

    2008-01-01

    As NPP (Nuclear Power Plant) gets aged, the importance of the pressure boundary integrity increases very much to those who are trying to operate their plant beyond its design life. Not long ago, Boric acid crystal was found at the RPV outlet nozzle of V.C. Summer plant during the visual examination in 2000. After this finding, non-destructive examination was taken to find out what's taken place. As a result of this examination, circumferential and axial cracks were found. With Metallurgical structure examination, it was shown that crack had been developed at the mid-point between Inco-alloy buttering and weld metal. It was turned out that high welding residual stress was the main cause of the cracking. Because of the through wall crack, nozzle and welding parts were replaced. Many other nuclear power plants experienced similar pressure boundary stress corrosion cracks (SCCs). KEPRI (Korea Electric Power Research Institute) has carried out research projects for managing and preventing these kinds of cracks in nuclear power plants (NPPs). The titles of these research projects are 'Development of Stress Corrosion Cracking Management Technology and Aging Monitor for NPP Main Components' and 'Development of Analysis Technology for Crack Management of Dissimilar Metal Weld'. Through these projects, residual stress measurement techniques have been exercised at various points in mock-up test specimens to simulate nuclear power plant dissimilar base metal and weldment residual stress. X-ray test and hole drilling method have been reviewed to measure residual stresses of the dissimilar metal welds. This paper shows some point of view in residual stress measurement. Fracture mechanics analysis has been performed to explain the importance of residual stress measurement in association with nuclear power plant safety

  16. High level compressive residual stresses produced in aluminum alloys by laser shock processing

    International Nuclear Information System (INIS)

    Gomez-Rosas, G.; Rubio-Gonzalez, C.; Ocana, J.L; Molpeceres, C.; Porro, J.A.; Chi-Moreno, W.; Morales, M.

    2005-01-01

    Laser shock processing (LSP) has been proposed as a competitive alternative technology to classical treatments for improving fatigue and wear resistance of metals. We present a configuration and results for metal surface treatments in underwater laser irradiation at 1064 nm. A convergent lens is used to deliver 1.2 J/cm 2 in a 8 ns laser FWHM pulse produced by 10 Hz Q-switched Nd:YAG, two laser spot diameters were used: 0.8 and 1.5 mm. Results using pulse densities of 2500 pulses/cm 2 in 6061-T6 aluminum samples and 5000 pulses/cm 2 in 2024 aluminum samples are presented. High level of compressive residual stresses are produced -1600 MPa for 6061-T6 Al alloy, and -1400 MPa for 2024 Al alloy. It has been shown that surface residual stress level is higher than that achieved by conventional shot peening and with greater depths. This method can be applied to surface treatment of final metal products

  17. Residual stresses in 2 1/4Cr1Mo welds

    International Nuclear Information System (INIS)

    Fidler, R.; Jerram, K.

    1978-01-01

    Two separate investigations, initiated in an attempt to explain the large amount of residual stress scatter previously observed in the weld metal of eighteen nominally identical thick-section 2 1/4Cr1Mo butt welds, are described in this paper. The first examined the detailed surface residual stress distributions in 2 1/4Cr1Mo manual arc circumferential butt welds in 80mm and 100mm thick 1/2Cr1/2Mo1/4V steam pipe. High residual stresses were found in the regions of overlap between adjacent weld beads, with low values in virgin weld metal. The second utilised single pass manual metal arc bead-in-groove welds to investigate the effects of preheat and weld metal composition on weld metal residual stresses. In four weld metals, mild steel, 1/2Cr1/2Mo1/4V, 1Cr1/2Mo, and 2 1/4Cr1Mo, the residual stresses were very similar, becoming less tensile (or more compressive) with increase of preheat, while the residual stresses in the fifth weld metal (12Cr) were significantly different, being compressive and less affected by preheat. In both investigations the effects have been described in terms of the basic metallurgical phenomena occurring in the weld metal. (author)

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

    Energy Technology Data Exchange (ETDEWEB)

    Robinson, J.S., E-mail: jeremy.robinson@ul.ie [Department of Mechanical, Aeronautical and Biomedical Engineering, University of Limerick (Ireland); Redington, W. [Materials and Surface Science Institute, University of Limerick (Ireland)

    2015-07-15

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

  19. Residual stress analysis in reactor pressure vessel attachments

    International Nuclear Information System (INIS)

    Dexter, R.J.; Pont, D.

    1991-08-01

    Residual stresses in cladding and welded attachments could contribute to the problem of stress-corrosion cracking in boiling-water reactors (BWR). As part of a larger program aimed at quantifying residual stress in BWR components, models that would be applicable for predicting residual stress in BWR components are reviewed and documented. The review includes simple methods of estimating residual stresses as well as advanced finite-element software. In general, simple methods are capable of predicting peak magnitudes of residual stresses but are incapable of adequately characterizing the distribution of residual stresses. Ten groups of researchers using finite-element software are reviewed in detail. For each group, the assumptions of the model, possible simplifications, material property data, and specific applications are discussed. The most accurate results are obtained when a metallurgical simulation is performed, transformation plasticity effects are included, and the heating and cooling parts of the welding thermal cycle are simulated. Two models are identified which can provide these features. The present state of these models and the material property data available in the literature are adequate to quantify residual stress in BWR components

  20. Effects of the magnesium oxide thin films' microstructures on the residual stresses

    Energy Technology Data Exchange (ETDEWEB)

    He, Li-jun, E-mail: helijun4@126.com [The School of Optoelectronic Engineering, Chongqing University of Posts and Telecommunications, Chongqing 400065 (China); The State Key Laboratory of Electronic Thin Films and Integrated Devices, School of Microelectronics and Solid-State Electronics, University of Electronic Science and Technology of China, Chengdu 610054 (China); Wang, Li-yan [Electronic Information and Networking Research Institute, Collaborative Innovation Center for Information Communication Technology, Chongqing University of Posts and Telecommunications, Chongqing 400065 (China); Chen, Wei-Zhong [The School of Optoelectronic Engineering, Chongqing University of Posts and Telecommunications, Chongqing 400065 (China); Liu, Xing-zhao [The State Key Laboratory of Electronic Thin Films and Integrated Devices, School of Microelectronics and Solid-State Electronics, University of Electronic Science and Technology of China, Chengdu 610054 (China)

    2016-09-15

    The MgO thin films are deposited at various inclined angles. The morphology investigated by scanning electron microscope (SEM) shows the MgO thin films deposited at high inclined angles have columnar grain. The relationships between full width high maximum (FWHM) of ω-scan, residual stresses and the inclined angles are studied. The results show the smallest FWHM of MgO (002) is 4.968°, the residual stress of MgO thin films is compressive stress, and the residual stress of MgO thin films deposited at the inclined angle of 55° is the smallest. So the microstructures of MgO thin films fabricated by the oblique angle deposition (OAD) technique effectively control the residual stresses. - Highlights: • MgO thin films are deposited by oblique angle deposition technique. • The FWHMs of MgO is the smallest at the inclined angle of 55°. • Residual stress of MgO is the smallest at the inclined angle of 55°.

  1. Residual stress in sprayed Ni+5%Al coatings determined by neutron diffraction

    CERN Document Server

    Matejicek, J; Gnaeupel-Herold, T; Prask, H J

    2002-01-01

    Coatings of nickel-based alloys are used in numerous high-performance applications. Their properties and lifetimes are influenced by factors such as residual stress. Neutron diffraction is a powerful tool for nondestructive residual stress determination. In this study, through-thickness residual stress profiles in Ni+5%Al coatings on steel substrates were determined. Two examples of significantly different spraying techniques - plasma spraying and cold spraying - are highlighted. Different stress-generation mechanisms are discussed with respect to process parameters and material properties. (orig.)

  2. Calculation method for residual stress analysis of filament-wound spherical pressure vessels

    International Nuclear Information System (INIS)

    Knight, C.E. Jr.

    1976-01-01

    Filament wound spherical pressure vessels may be produced with very high performance factors. These performance factors are a calculation of contained pressure times enclosed volume divided by structure weight. A number of parameters are important in determining the level of performance achieved. One of these is the residual stress state in the fabricated unit. A significant level of an unfavorable residual stress state could seriously impair the performance of the vessel. Residual stresses are of more concern for vessels with relatively thick walls and/or vessels constructed with the highly anisotropic graphite or aramid fibers. A method is established for measuring these stresses. A theoretical model of the composite structure is required. Data collection procedures and techniques are developed. The data are reduced by means of the model and result in the residual stress analysis. The analysis method can be used in process parameter studies to establish the best fabrication procedures

  3. Residual stress measurement of large scaled welded pipe using neutron diffraction method. Effect of SCC crack propagation and repair weld on residual stress distribution

    International Nuclear Information System (INIS)

    Suzuki, Hiroshi; Katsuyama, Jinya; Tobita, Tohru; Morii, Yukio

    2011-01-01

    The RESA-1 neutron engineering diffractometer in the JRR-3 (Japan Research Reactor No.3) at the Japan Atomic Energy Agency, which is used for stress measurements, was upgraded to realize residual stress measurements of large scaled mechanical components. A series of residual stress measurements was made to obtain through-thickness residual stress distributions in a Type 304 stainless steel butt-welded pipe of 500A-sch.80 using the upgraded RESA-1 diffractometer. We evaluated effects of crack propagation such as stress corrosion cracking (SCC) and a part-circumference repair weld on the residual stress distributions induced by girth welding. Measured residual stress distributions near original girth weld revealed good agreement with typical results shown in some previous works using finite element method, deep hole drilling as well as neutron diffraction. After introducing a mock crack with 10 mm depth in the heat affected zone on the inside wall of the pipe by electro discharge machining, the axial residual stresses were found to be released in the part of the mock crack. However, changes in the through-wall bending stress component and the self-equilibrated stress component were negligible and hence the axial residual stress distribution in the ligament was remained in the original residual stresses near girth weld without the mock crack. Furthermore, changes in hoop and radial residual stress were also small. The residual stress distributions after a part repair welding on the outer circumference of the girth weld were significantly different from residual stress distributions near the original girth weld. The through-thickness average axial residual stress was increased due to increase of the tensile membrane stress and mitigation of the bending stress after repair welding. Throughout above studies, we evidenced that the neutron diffraction technique is useful and powerful tool for measuring residual stress distributions in large as well as thick mechanical

  4. X-Ray Diffraction Techniques and Finite Element Modeling to Control Residual Stress in High-Temperature Pressure Vessels

    National Research Council Canada - National Science Library

    Lee, S

    1999-01-01

    Manufacturing operations, such as swage autofrettage, shot peening, and overload processes, have been used to impart advantageous residual stresses to improve fatigue life in components used in high...

  5. Residual stress analysis in thick uranium films

    International Nuclear Information System (INIS)

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

    2005-01-01

    Residual stress analysis was performed on thick, 1-25 μm, depleted uranium (DU) films deposited on an Al substrate by magnetron sputtering. Two distinct characterization techniques were used to measure substrate curvature before and after deposition. Stress evaluation was performed using the Benabdi/Roche equation, which is based on beam theory of a bi-layer material. The residual stress evolution was studied as a function of coating thickness and applied negative bias voltage (0, -200, -300 V). The stresses developed were always compressive; however, increasing the coating thickness and applying a bias voltage presented a trend towards more tensile stresses and thus an overall reduction of residual stresses

  6. Design of specimen for weld residual stress simulation

    International Nuclear Information System (INIS)

    Kim, Jin Weon; Park, Jong Sun; Lee, Kyung Soo

    2008-01-01

    The objective of this study is to design a laboratory specimen for simulating residual stress of circumferential butt welding of pipe. Specimen type and method for residual stress generation were proposed based on the review of prior studies and parametric finite element simulation. To prove the proposed specimen type and loading method, the residual stress was generated using the designed specimen by applying proposed method and was measured. The measured residual stress using X-ray diffraction reasonably agreed with the results of finite element simulation considered in the specimen design. Comparison of residual strains measured at several locations of specimen and given by finite element simulation also showed good agreement. Therefore, it is indicated that the designed specimen can reasonably simulate the residual stress of circumferential butt welding of pipe

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

    Science.gov (United States)

    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

  8. Residual stress development and relief in high strength aluminium alloys using standard and retrogression thermal treatments

    OpenAIRE

    Robinson, J.S; Tanner, D.A

    2003-01-01

    peer-reviewed Residual stresses develop in the aluminium alloy 7010 when the material is quenched from the solution heat treatment temperature. Residual stress measurements have been made using the X-ray diffraction technique and a longitudinal split sawcut method to determine the magnitude of residual stress that develops in specimens sectioned from large open die forgings as a result of (a) quenching these specimens into water at different temperatures, and (b) cold water quenching from ...

  9. Residual stress in spin-cast polyurethane thin films

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, Hong; Zhang, Li, E-mail: lizhang@mae.cuhk.edu.hk [Department of Mechanical and Automation Engineering, The Chinese University of Hong Kong, Shatin N.T., Hong Kong (China); Chow Yuk Ho Technology Centre for Innovative Medicine, The Chinese University of Hong Kong, Shatin N.T., Hong Kong (China)

    2015-01-19

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

  10. Residual stress studies of austenitic and ferritic steels

    International Nuclear Information System (INIS)

    Chrenko, R.M.

    1978-01-01

    Residual studies have been made on austenitic and ferritic steels of the types used as structural materials. The residual stress results presented here will include residual stress measurements in the heat-affected zone on butt welded Type 304 stainless steel pipes, and the stresses induced in Type 304 austenitic stainless steel and Type A508 ferritic steel by several surface preparations. Such surface preparation procedures as machining and grinding can induce large directionality effects in the residual stresses determined by X-ray techniques and some typical data will be presented. A brief description is given of the mobile X-ray residual stress apparatus used to obtain most of the data in these studies. (author)

  11. Residual stress measurements by means of neutron diffraction

    International Nuclear Information System (INIS)

    Pintschovius, L.; Jung, V.; Macherauch, E.; Voehringer, O.

    1983-01-01

    A new method for the analysis of multiaxial residual stress states is presented, which is based on high resolution neutron diffraction. It is analogous to X-ray stress analysis, but the use of neutrons instead of X-rays allows the analysis of the stress distributions also in the interior of technical components in a non-destructive way. To prove the feasibility of the method, investigations of the loading stress distributions of an aluminium bar subjected to purely elastic bending were performed. Limiting factors due to the volume of the internal probe region and the sample thickness are discussed. Complete neutron residual stress analyses were carried out for a plastically deformed bending bar and a transformation-free water-quenched steel cylinder. The results are in fairly good agreement with theoretical expectations and with X-ray control measurements at the surface of the objects. (Auth.)

  12. Evaluation of Residual Stresses using Ring Core Method

    Directory of Open Access Journals (Sweden)

    Holý S.

    2010-06-01

    Full Text Available The method for measuring residual stresses using ring-core method is described. Basic relations are given for residual stress measurement along the specimen depth and simplified method is described for average residual stress estimation in the drilled layer for known principal stress directions. The estimation of calculated coefficients using FEM is described. Comparison of method sensitivity is made with hole-drilling method. The device for method application is described and an example of experiment is introduced. The accuracy of method is discussed. The influence of strain gauge rosette misalignment to the evaluated residual stresses is performed using FEM.

  13. Residual Stress Measurement of SiC tile/Al7075 Hybrid Composites by Neutron Diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Park, Jong Bok; Lee, Jun Ho; Hong, Soon Hyung; Ryu, Ho Jin [KAIST, Daejeon (Korea, Republic of); Lee, Sang Bok; Lee, Sang Kwan [Korea Institute of Materials Science, Changwon (Korea, Republic of); Muslihd, M. Rifai [Center for Advanced Materials Science and Technology, Tangerang (India)

    2016-05-15

    In this research, SiC which has low density, high compressive strength, and high elastic modulus was used to fabricate the armor plate. In addition, Al which has low density and high toughness was used for a metal matrix of the composites. If two materials are combined, the composite can be effective materials for light weight armor applications. However, the existence of a large difference in coefficients of thermal expansion (CTE) between SiC and Al matrix, SiC/Al composites can have residual stresses while cooled in the fabrication process. Previous research reported that residual stresses in the composites or microstructures have an effect on the fatigue life and their mechanical properties. Some researchers reported about the residual stresses in the SiCp/Al metal matrix composites by numerical simulation systems, X-ray diffraction, and destructive methods. In order to analyze the residual stress of SiC/Al composites, the neutron diffraction as the non-destructive method was performed in this research. The 50 vol.% SiC{sub p}/Al7075 composites and SiC tile inserted 50 vol.% SiC{sub p}/Al7075 hybrid composites were measured to analyze the residual stress of Al (111) and SiC (111). Both samples had the tensile residual stresses in the Al (111) and the compressive residual stresses in the SiC (111) due to the difference in CTE.

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

    Science.gov (United States)

    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

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

    International Nuclear Information System (INIS)

    Hayashi, Makoto; Ishiwata, Masayuki; Minakawa, Noriaki; Funahashi, Satoru.

    1995-01-01

    Neutron diffraction measurements of lattice spacings provide the spatial map of residual stress near welds in ferritic steel socket joints. The high tensile stress greater than 200 MPa was found in the fusion and heat-affected zones in the hoop direction. However, the highest tensile stress in the axial direction at the weld root was about 110 MPa relatively lower than the expected value from the fatigue test results. The balancing compressive stress was found near the surface of the socket weld fusion zone. Heat treatment at 625degC for 2 hours was sufficient for the relief of residual stress in socket welds. (author)

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

    Science.gov (United States)

    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.

  17. Residual stresses in Inconel 718 engine disks

    Directory of Open Access Journals (Sweden)

    Dahan Yoann

    2014-01-01

    Full Text Available Aubert&Duval has developed a methodology to establish a residual stress model for Inconel 718 engine discs. To validate the thermal, mechanical and metallurgical parts of the model, trials on lab specimens with specific geometry were carried out. These trials allow a better understanding of the residual stress distribution and evolution during different processes (quenching, ageing, machining. A comparison between experimental and numerical results reveals the residual stresses model accuracy. Aubert&Duval has also developed a mechanical properties prediction model. Coupled with the residual stress prediction model, Aubert&Duval can now propose improvements to the process of manufacturing in Inconel 718 engine disks. This model enables Aubert&Duval customers and subcontractors to anticipate distortions issues during machining. It could also be usedt to optimise the engine disk life.

  18. Residual stresses and mechanical properties of metal matrix composites

    International Nuclear Information System (INIS)

    Persson, Christer.

    1993-01-01

    The large difference in coefficient of thermal expansion of the matrix and particles in a metal matrix composite will introduce residual stresses during cooling from process temperature. These stresses are locally very high, and are known to influence the mechanical behaviour of the material. Changes in the stress state will occur during heat treatments and when the material is loaded due to different elastic, plastic, and creep properties of the constituents. The change of residual stresses in an Al-SiC particulate composite after different degree of plastic straining has been studied. The effect of plastic straining was modelled by an Eshelby model. The model and the measurements both show that the stress in the loading direction decreases for a tensile plastic strain and increases for a compressive plastic strain. By x-ray diffraction the stress response in the matrix and particles can be measured independently. This has been used to determine the stress state under and after heat treatments and under mechanical loading in two Al 15% SiC metal matrix composites. By analysing the line width from x-ray experiment the changes in the microstrains in the material were studied. A finite element model was used to model the generation of thermal residual stresses, stress relaxation during heat treatments, and load sharing during the first load cycle. Calculated stresses and microstrains were found to be in good agreement with the measured values. The elastic behaviour of the composite can be understood largely in terms of elastic load transfer between matrix and particles. However, at higher loads when the matrix becomes plastic residual stresses also become important. 21 refs

  19. Residual Stress Analysis Based on Acoustic and Optical Methods

    Directory of Open Access Journals (Sweden)

    Sanichiro Yoshida

    2016-02-01

    Full Text Available 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.

  20. X-ray measurement of residual stress on bolt threads

    International Nuclear Information System (INIS)

    Hagiwara, Masaya; Nakahara, Kanefumi; Yoshimoto, Isamu.

    1989-01-01

    This study deals with X-ray measurement of residual stress at the local area around the thread root of a bolt. Residual stress in the 0.5 mm x 5 mm area was measured using a method of stepped scanning and parabolic approximation. The conditions of measurement had been determined and evaluated through the preliminary measurement of compressive stress acting on the cylindrical surface. Furthermore, the fatigue strength estimated by applying the residual stress data to the previously presented hypothesis was compared with the experimental results. The main conclusions obtained were as follows: (1) The residual stress in a relatively small area on the cylindrical surface with large curvature can be measured by X-ray using a method of stepped scanning and parabolic approximation; (2) The compressive residual stress measured at the thread root was larger for the bolt manufactured by thread rolling after heat treatment than for one manufactured by thread rolling before heat treatment; (3) The distribution of residual stress along the axial direction from the thread root to the portion under crest did not represent remarkable change in its value; (4) The residual stress of a bolt was somewhat decreased by fatigue loading on the condition of low mean stress; (5) The fatigue strength estimated using residual stress data showed the tendency of experimental results well. (author)

  1. Reduction method for residual stress of welded joint using harmonic vibrational load

    International Nuclear Information System (INIS)

    Aoki, Shigeru; Nishimura, Tadashi; Hiroi, Tetsumaro; Hirai, Seiji

    2007-01-01

    Welding is widely used for construction of many structures. Since welding is a process using locally given heat, residual stress is generated near the bead. Tensile residual stress degrades fatigue strength. Some reduction methods of residual stress have been presented and, for example, heat treatment and shot peening are practically used. However, those methods need special tools and are time consuming. In this paper, a new method for reduction of residual stress using harmonic vibrational load during welding is proposed. The proposed method is examined experimentally for some conditions. Two thin plates are supported on the supporting device and butt-welded using an automatic CO 2 gas shielded arc welding machine. Residual stress in the direction of the bead is measured by using a paralleled beam X-ray diffractometer with scintillation counter after removing quenched scale chemically. First, the welding of rolled steel for general structure for some excitation frequencies is examined. Specimens are welded along the groove on both sides. For all frequencies, tensile residual stress near the bead is significantly reduced. Second, welding of the specimen made of high tensile strength steel is examined. In this case, tensile residual stress near the bead is also reduced. Finally, the proposed method is examined by an analytical method. An analytical model which consists of mass and preloaded springs with elasto-plastic characteristic is used. Reduction of residual stress is demonstrated using this model

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

    Science.gov (United States)

    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.

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

    Science.gov (United States)

    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.

  4. High energy X-ray diffraction analysis of strain and residual stress in silicon nitride ceramic diffusion bonds

    International Nuclear Information System (INIS)

    Vila, M.; Prieto, C.; Miranzo, P.; Osendi, M.I.; Terry, A.E.; Vaughan, G.B.M.

    2005-01-01

    High resolution X-ray scanning diffractometry is used to study the residual stress in binary metal/ceramic (Ni/Si 3 N 4 ) diffusion bonds fabricated by simultaneous high temperature heating and uniaxial pressing. In order to diminish the experimental error on the stress determination, the method consists of three steps: (i) to measure the axial and radial strains following some selected lines at the inner volume of the ceramic; (ii) to fit the strain data using finite element method (FEM) analysis and (iii) to determinate stresses by using the results obtained from the FEM method in the strain calculation

  5. On machine surface to the unit event causing residual stress

    International Nuclear Information System (INIS)

    Arunachalama, R.M.; Mannanb, M.A.; Spowageca, A.

    2005-01-01

    Integrity and reduce overall costs. Within the framework of surface integrity investigations, special emphasis is given to the measurement of residual stresses because they contribute directly to premature failure of components. Since the highest residual stresses are to be found in surface layers, these deserve special attention when dealing with dynamically, heavily loaded machine parts such as gas turbine components used in aero engines. Of the many techniques available for the measurement of residual stresses, the most highly developed and widely used non-destructive method is based on X-ray diffraction (XRD). However, it is not possible to use this technique for inspection of all the components, since it is time consuming, complicated as well as expensive. In this paper, a method is being proposed that augments the XRD method but at the same time capable of inspecting all the components. A non-destructive, visual inspection technique has been developed that can correlate the characteristic features on the surface to the unit event causing the residual stress and the type of residual stress generated on the machined surface. Pictures of the machined surfaces have been taken using a digital video microscope at a magnification of 500 and the surface feature correlated to the unit event causing the residual stress. Sharp and well defined long grooves indicate that the plastic deformation is dominated by a mechanical unit event while appearance of streaks and small areas of smeared material indicate that the plastic deformation is dominated by a thermal unit event. These trends have been confirmed by measuring the residual stresses using XRD. The proposed technique is an attempt at establishing a simple methodology that would be useful to industries manufacturing aerospace and other components that require good surface integrity. (Author)

  6. Residual stress in Ni-W electrodeposits

    DEFF Research Database (Denmark)

    Mizushima, Io; Tang, Peter Torben; Hansen, Hans Nørgaard

    2006-01-01

    In the present work, the residual stress in Ni–W layers electrodeposited from electrolytes based on NiSO4 and Na2WO4, is investigated. Citrate, glycine and triethanolamine were used as complexing agents, enabling complex formation between the nickel ion and tungstate. The results show that the type...... of complexing agent and the current efficiency have an influence on the residual stress. In all cases, an increase in tensile stress in the deposit with time after deposition was observed. Pulse plating could improve the stress level for the electrolyte containing equal amounts of citrate...

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

    International Nuclear Information System (INIS)

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

    2012-01-01

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

  8. Neutron measurement of residual stresses in a used railway rail

    International Nuclear Information System (INIS)

    Webster, P.J.; Low, K.S.; Mills, G.; Webster, G.A.

    1990-01-01

    The high resolution neutron diffraction technique has been applied to determine, non-destructively, the residual stress distribution developed in the head of a railway rail after normal service. Measurements were made, using the neutron strain scanner at the Institute Laue Langevin, Grenoble, on a transverse slice of rail 12mm thick taken from a section of straight track. The rail head was scanned in the three principal orientations in a series of parallel traverses sufficiently close to enable a two-dimensional matrix of data to be accumulated and vertical, transverse and longitudinal residual stress contours to be drawn. The results demonstrate the effectiveness and unique characteristics of the neutron technique to determine nondestructively and continuously the residual stresses inside engineering components

  9. Effect of residual stress on the integrity of a branch connection

    International Nuclear Information System (INIS)

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

    2012-01-01

    A new connection to an existing gas pipeline was made by hot-tapping, welding directly onto a pressurised pipeline. The welds were not post-weld heat treated, causing significant residual stresses. The critical weld had residual stresses determined by neutron diffraction using ANSTO's residual stress diffractometer, Kowari. The maximum measured residual stress (290 MPa) was 60% of the yield strength. The magnitudes of errors from a number of sources were estimated. An integrity assessment of the welded branch connection was performed with the measured residual stress values and with residual stress distributions from the BS 7910 and API 579 analysis codes. Analysis using estimates of residual stress from API 579 overestimated the critical crack size. Highlights: ► Residual stresses were measured by neutron diffraction in a thick section, non post-weld heat treated ferritic weld. ► There is little published data on these welds. ► The work compares the measured residual stresses with code-based residual stress distributions.

  10. Residual stress measurement in 304 stainless steel weld overlay pipes

    International Nuclear Information System (INIS)

    Yen, H.J.; Lin, M.C.C.; Chen, L.J.

    1996-01-01

    Welding overlay repair (WOR) is commonly employed to rebuild piping systems suffering from intergranular stress corrosion cracking (IGSCC). To understand the effects of this repair, it is necessary to investigate the distribution of residual stresses in the welding pipe. The overlay welding technique must induce compressive residual stress at the inner surface of the welded pipe to prevent IGSCC. To understand the bulk residual stress distribution, the stress profile as a function of location within wall is examined. In this study the full destructive residual stress measurement technique -- a cutting and sectioning method -- is used to determine the residual stress distribution. The sample is type 304 stainless steel weld overlay pipe with an outside diameter of 267 mm. A pipe segment is cut from the circular pipe; then a thin layer is removed axially from the inner to the outer surfaces until further sectioning is impractical. The total residual stress is calculated by adding the stress relieved by cutting the section away to the stress relieved by axially sectioning. The axial and hoop residual stresses are compressive at the inner surface of the weld overlay pipe. Compressive stress exists not only at the surface but is also distributed over most of the pipe's cross section. On the one hand, the maximum compressive hoop residual stress appears at the pipe's inner surface. The thermal-mechanical induced crack closure from significant compressive residual stress is discussed. This crack closure can thus prevent IGSCC very effectively

  11. Study of residual stresses generated in machining of AISI 4340 steel

    International Nuclear Information System (INIS)

    Reis, W.P. dos; Fonseca, M.P. Cindra; Serrao, L.F.; Chuvas, T.C.; Oliveira, L.C.

    2010-01-01

    Among the mechanical construction steels, AISI 4340 has good harden ability, while combining high strength with toughness and good fatigue strength, making it excellent for application in the metalworking industry, where it can work at different levels and types of requests. Residual stresses are generated in almost all processes of mechanical manufacturing. In this study, the residual stresses generated in different machining processes and heat treatment hardening of AISI 4340 were analyzed by X-ray diffraction, by the sen 2 ψ method, using Crκβ radiation and compared. All samples, except for turned and cut by EDM, presented compressive residual stresses in the surface with various magnitudes. (author)

  12. The method for measuring residual stress in stainless steel pipes

    International Nuclear Information System (INIS)

    Shimov, Georgy; Rozenbaum, Mikhail; Serebryakov, Alexandr; Serebryakov, Andrey

    2016-01-01

    The main reason of appearance and growth of corrosion damages of the nuclear steam generator heat exchanger tubes is the process of stress-corrosion cracking of metal under the influence of residual tensile stress. Methods used in the production for estimating residual stresses (such as a method of ring samples) allow measuring only the average tangential stress of the pipe wall. The method of ring samples does not allow to assess the level of residual stress in the surface layer of the pipe. This paper describes an experimental method for measuring the residual stresses on the pipe surface by etching a thin surface layer of the metal. The construction and working principle of a trial installation are described. The residual stresses in the wall of the tubes 16 × 1.5 mm (steel AISI 321) for nuclear steam generators is calculated. Keywords: heat exchange pipes, stress corrosion cracking, residual stresses, stress distribution, stress measurement.

  13. Residual stress effects in LMFBR fracture assessment procedures

    International Nuclear Information System (INIS)

    Hooton, D.G.

    1984-01-01

    Two post-yield fracture mechanics methods, which have been developed into fully detailed failure assessment procedures for ferritic structures, have been reviewed from the point of view of the manner in which as-welded residual stress effects are incorporated, and comparisons then made with finite element and theoretical models of centre-cracked plates containing residual/thermal stresses in the form of crack-driving force curves. Applying the procedures to austenitic structures, comparisons are made in terms of failure assessment curves and it is recommended that the preferred method for the prediction of critical crack sizes in LMFBR austenitic structures containing as-welded residual stresses is the CEGB-R6 procedure based on a flow stress defined at 3% strain in the parent plate. When the prediction of failure loads in such structures is required, it is suggested that the CEGB-R6 procedure be used with residual/thermal stresses factored to give a maximum total stress of flow stress magnitude

  14. Modelling of the Residual Stress State in a new Type of Residual Stress Specimen

    DEFF Research Database (Denmark)

    Jakobsen, Johnny; Andreasen, Jens Henrik

    2014-01-01

    forms the experimental case which is analysed. A FE model of the specimen is used for analysing the curing history and the residual stress build up. The model is validated against experimental strain data which are recorded by a Fibre Brag Grating sensor and good agreement has been achieved.......The paper presents a study on a new type residual stress specimen which is proposed as a simple way to conduct experimental validation for model predictions. A specimen comprising of a steel plate with circular hole embedded into a stack of CSM glass fibre and further infused with an epoxy resin...

  15. Investigating Resulting Residual Stresses during Mechanical Forming Process

    Science.gov (United States)

    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.

  16. Effect of processing conditions on residual stress distributions by bead-on-plate welding after surface machining

    International Nuclear Information System (INIS)

    Ihara, Ryohei; Mochizuki, Masahito

    2014-01-01

    Residual stress is important factor for stress corrosion cracking (SCC) that has been observed near the welded zone in nuclear power plants. Especially, surface residual stress is significant for SCC initiation. In the joining processes of pipes, butt welding is conducted after surface machining. Residual stress is generated by both processes, and residual stress distribution due to surface machining is varied by the subsequent butt welding. In previous paper, authors reported that residual stress distribution generated by bead on plate welding after surface machining has a local maximum residual stress near the weld metal. The local maximum residual stress shows approximately 900 MPa that exceeds the stress threshold for SCC initiation. Therefore, for the safety improvement of nuclear power plants, a study on the local maximum residual stress is important. In this study, the effect of surface machining and welding conditions on residual stress distribution generated by welding after surface machining was investigated. Surface machining using lathe machine and bead on plate welding with tungsten inert gas (TIG) arc under various conditions were conducted for plate specimens made of SUS316L. Then, residual stress distributions were measured by X-ray diffraction method (XRD). As a result, residual stress distributions have the local maximum residual stress near the weld metal in all specimens. The values of the local maximum residual stresses are almost the same. The location of the local maximum residual stress is varied by welding condition. It could be consider that the local maximum residual stress is generated by same generation mechanism as welding residual stress in surface machined layer that has high yield stress. (author)

  17. Development of residual stress analysis procedure for fitness-for-service assessment of welded structure

    International Nuclear Information System (INIS)

    Kim, Jong Sung; Jin, Tae Eun; Dong, P.; Prager, M.

    2003-01-01

    In this study, a state of art review of existing residual stress analysis techniques and representative solutions is presented in order to develop the residual stress analysis procedure for Fitness-For-Service(FFS) assessment of welded structure. Critical issues associated with existing residual stress solutions and their treatments in performing FFS are discussed. It should be recognized that detailed residual stress evolution is an extremely complicated phenomenon that typically involves material-specific thermomechanical/metallurgical response, welding process physics, and structural interactions within a component being welded. As a result, computational procedures can vary significantly from highly complicated numerical techniques intended only to elucidate a small part of the process physics to cost-effective procedures that are deemed adequate for capturing some of the important features in a final residual stress distribution. Residual stress analysis procedure for FFS purposes belongs to the latter category. With this in mind, both residual stress analysis techniques and their adequacy for FFS are assessed based on both literature data and analyses performed in this investigation

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

    Science.gov (United States)

    2014-03-01

    University Press, 2009, pp. 820–824. [30] S. Kou, Welding Metallurgy , 2nd ed. Hoboken, NJ: John Wiley and Sons, Inc., 2003. [31] M. N.James et al...around welds in aluminum ship structures both in the laboratory and in the field. Tensile residual stresses are often generated during welding and, in...mitigate and even reverse these tensile residual stresses. This research uses x-ray diffraction to measure residual stresses around welds in AA5456 before

  19. Measurement of residual stress in textured Al alloy by neutron diffraction method

    International Nuclear Information System (INIS)

    Okido, S.; Hayashi, M.; Tanaka, K.; Akiniwa, Y.; Minakawa, N.; Morii, Y.

    1999-01-01

    Residual stress generated in a shrunken aluminum alloy specimen, which was prepared for the round robin test conducted by VAMAS (Versailles Project on Advanced Materials and Standards) TWA-20 organized for the purpose of standardizing residual stress measurement methods, was evaluated by a neutron diffraction method. The main purpose of the round robin test was to assess the reproducibility of data obtained with the measurement facilities of the participants. The general standard of the Residual Stress Analyzer (RESA) constructed in the Japan Atomic Energy Research Institute was verified from the measured residual strains, which were equivalent to the values calculated by FEM and values measured by the research facilities in North America. Residual stress was calculated from residual strain in three perpendicular directions. The diffraction intensities were dependent on measurement directions since the prepared specimen possessed texture. Diffraction profiles in directions having a weak diffraction intensity caused an inaccurate evaluation of the residual stress. To solve this problem, a new method for evaluating residual stress with respect to diffraction plane dependency of the elastic constant was applied. The diffraction plane giving the highest intensity among 110, 200, and 220 diffraction was used to evaluate the residual strain in each of three directions. The residual strain obtained on the used diffraction plane was converted to the equivalent strain for the defined diffraction plane using the ratio of elastic constants of these two planes. The developed evaluation method achieved highly accurate measurement and remarkable efficiency in the measurement process. (author)

  20. Control of welding residual stress for ensuring integrity against fatigue and stress-corrosion cracking

    International Nuclear Information System (INIS)

    Mochizuki, Masahito

    2007-01-01

    The availability of several techniques for residual stress control is discussed in this paper. The effectiveness of these techniques in protecting from fatigue and stress-corrosion cracking is verified by numerical analysis and actual experiment. In-process control during welding for residual stress reduction is easier to apply than using post-weld treatment. As an example, control of the welding pass sequence for multi-pass welding is applied to cruciform joints and butt-joints with an X-shaped groove. However, residual stress improvement is confirmed for post-weld processes. Water jet peening is useful for obtaining a compressive residual stress on the surface, and the tolerance against both fatigue and stress-corrosion cracking is verified. Because cladding with a corrosion-resistant material is also effective for preventing stress-corrosion cracking from a metallurgical perspective, the residual stress at the interface of the base metal is carefully considered. The residual stress of the base metal near the clad edge is confirmed to be within the tolerance of crack generation. Controlling methods both during and after welding processes are found to be effective for ensuring the integrity of welded components

  1. Residual stresses in laser direct metal deposited Waspaloy

    Energy Technology Data Exchange (ETDEWEB)

    Moat, R.J., E-mail: richard.moat@manchester.ac.uk [School of Materials, University of Manchester, Grosvenor Street, Manchester M1 7HS (United Kingdom); Pinkerton, A.J.; Li, L. [Laser Processing Research Centre, School of Mechanical, Aerospace and Civil Engineering, University of Manchester, M60 1QD (United Kingdom); Withers, P.J.; Preuss, M. [School of Materials, University of Manchester, Grosvenor Street, Manchester M1 7HS (United Kingdom)

    2011-03-15

    Research highlights: {yields} Neutron diffraction and the contour method show good agreement. {yields} Tensile stresses found parallel to the surfaces. {yields} Compressive stresses within the bulk of the structures. {yields} Residual stress weakly dependent on the laser pulse parameters. {yields} Maximum tensile residual stress unaffected across range of pulse parameters used. - Abstract: This paper reports a study into the effect of laser pulse length and duty cycle on the residual stress distributions in multi-track laser direct metal deposits of Waspaloy onto an Inconel 718 substrate. The residual stresses have been evaluated using neutron diffraction and the contour method, while electron microscopy and micro hardness indentation have been used to map the concomitant microstructural variation. In all cases, near the tops of the deposited walls, the longitudinal stresses are tensile towards the mid-length of the wall, while the stresses perpendicular to the substrate are negligible. By contrast near the base of the walls, the stresses along the direction of deposition are small, while the stresses perpendicular to the substrate are compressive at the centre and tensile towards the ends. Consistent with previous observations, the stresses parallel to free surfaces are tensile, balanced by compressive stresses in the interior (an inverse quench stress profile). These profiles have been found to be weakly dependent on the laser pulse parameters, most notably an increase in tensile stress gradient with increasing duty cycle, but the maximum residual stresses are largely unaffected. Furthermore, microstructural analysis has shown that the effect of laser pulse parameters on grain morphology in multi-track thick walls is less marked than previously reported for single-track wall structures.

  2. Residual stresses in laser direct metal deposited Waspaloy

    International Nuclear Information System (INIS)

    Moat, R.J.; Pinkerton, A.J.; Li, L.; Withers, P.J.; Preuss, M.

    2011-01-01

    Research highlights: → Neutron diffraction and the contour method show good agreement. → Tensile stresses found parallel to the surfaces. → Compressive stresses within the bulk of the structures. → Residual stress weakly dependent on the laser pulse parameters. → Maximum tensile residual stress unaffected across range of pulse parameters used. - Abstract: This paper reports a study into the effect of laser pulse length and duty cycle on the residual stress distributions in multi-track laser direct metal deposits of Waspaloy onto an Inconel 718 substrate. The residual stresses have been evaluated using neutron diffraction and the contour method, while electron microscopy and micro hardness indentation have been used to map the concomitant microstructural variation. In all cases, near the tops of the deposited walls, the longitudinal stresses are tensile towards the mid-length of the wall, while the stresses perpendicular to the substrate are negligible. By contrast near the base of the walls, the stresses along the direction of deposition are small, while the stresses perpendicular to the substrate are compressive at the centre and tensile towards the ends. Consistent with previous observations, the stresses parallel to free surfaces are tensile, balanced by compressive stresses in the interior (an inverse quench stress profile). These profiles have been found to be weakly dependent on the laser pulse parameters, most notably an increase in tensile stress gradient with increasing duty cycle, but the maximum residual stresses are largely unaffected. Furthermore, microstructural analysis has shown that the effect of laser pulse parameters on grain morphology in multi-track thick walls is less marked than previously reported for single-track wall structures.

  3. Tensile Residual Stress Mitigation Using Low Temperature Phase Transformation Filler Wire in Welded Armor Plates

    Energy Technology Data Exchange (ETDEWEB)

    Feng, Zhili [ORNL; Bunn, Jeffrey R [ORNL; Tzelepis, Demetrios A [ORNL; Payzant, E Andrew [ORNL; Yu, Xinghua [ORNL

    2016-01-01

    Hydrogen induced cracking (HIC) has been a persistent issue in welding of high-strength steels. Mitigating residual stresses is one of the most efficient ways to control HIC. The current study develops a proactive in-process weld residual stress mitigation technique, which manipulates the thermal expansion and contraction sequence in the weldments during welding process. When the steel weld is cooled after welding, martensitic transformation will occur at a temperature below 400 C. Volume expansion in the weld due to the martensitic transformation will reduce tensile stresses in the weld and heat affected zone and in some cases produce compressive residual stresses in the weld. Based on this concept, a customized filler wire which undergoes a martensitic phase transformation during cooling was developed. The new filler wire shows significant improvement in terms of reducing the tendency of HIC in high strength steels. Bulk residual stress mapping using neutron diffraction revealed reduced tensile and compressive residual stresses in the welds made by the new filler wire.

  4. Effect of residual stresses on hydrogen permeation in iron

    International Nuclear Information System (INIS)

    Mouanga, M.; Bercot, P.; Takadoum, J.

    2010-01-01

    The effect of residual stresses on electrochemical permeation in iron membrane was investigated. Four thermal and mechanical treatments were chosen to obtain different surface states in relation to the residual stresses. Residual stresses were determined by X-ray diffraction (XRD) using the Macherauch and Mueller method. The results were completed by the microhardness measurements. For all iron membranes, compressive residual stresses were obtained. Electrochemical permeation experiments using a Devanathan and Stachurski cell were employed to determine the hydrogen permeation behaviour of the various iron membranes. The latter was charged with hydrogen by galvanostatic cathodic polarization in 0.1 M NaOH at 25 deg. C. The experimental results revealed that hydrogen permeation rate increases with increasing residual stresses introduced in iron membranes.

  5. Measuring depth profiles of residual stress with Raman spectroscopy

    Energy Technology Data Exchange (ETDEWEB)

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

    1988-12-01

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

  6. Comparison of welding induced residual stresses austenitic and ferritic steel weld joints

    International Nuclear Information System (INIS)

    Rajkumar, K.V.; Arun Kumar, S.; Mahadevan, S.; Manojkumar, R.; Rao, B. Purna Chandra; Albert, Shaju K.; Murugan, S.

    2015-01-01

    X-ray diffraction (XRD) is a well established technique for measurement of residual stresses in components and is being widely used. In XRD technique, the distance between the crystallographic planes (d spacing) is measured from peak position (2è) at various ø angles, where ø is the angle between the normal to the sample and the bisector of the incident and diffracted beam. From the slope of sin2ø vs. d spacing plot, the residual stresses are arrived by assuming a plane stress model. Welding induced residual stresses is of high importance as it is a major cause of failure in components. Surface compressive stresses improve the fatigue strength, whereas tensile residual stresses tend to decrease the fatigue strength. The present study compares the residual stresses that develop in 3 mm thick SS 316 and P91 TIG weld joints using the XRD technique. This study is aimed at understanding the influence of shrinkage during cooling and the effect of phase transformation induced volume changes on residual stress development in these two steels. While the first effect is predominant in the SS 316 weld, both the effects are present in the P91 welds. Stress measurements on SS 316 and P91 were carried out using Cr Kâ (λ-2.0840 Å) and Cr Ká (λ-2.2896 Å) radiations respectively. Typical 'M' type stress profile was observed across the weld centre line in both the welds. The variation and similarities between the longitudinal stress profiles observed in these two weld joints would be discussed. (author)

  7. Compressive residual stresses as a preventive measure against stress corrosion cracking on turbine components

    International Nuclear Information System (INIS)

    Berger, C.; Ewald, J.; Fischer, K.; Gruendler, O.; Potthast, E.; Stuecker, E.; Winzen, G.

    1987-01-01

    Disk type low pressure turbine rotors have been designed for a large variety of power plant applications. Developing disk type rotors required a concerted effort to design a shaft/disk shrink fit with a minimum of tensile stress concentrations in order to aim for the lowest possible susceptibility to corrosive attack, i.e. stress corrosion cracking. As a result of stresses, the regions of greatest concern are the shrink fit boundaries and the keyways of turbine disks. These stresses are caused by service loading, i.e. centrifugal and shrinkage stresses and by manufacturing procedure, i.e. residual stresses. The compressive residual stresses partly compensate the tensile service stresses so that an increase of compressive residual stresses decreases the whole stress state of the component. Special manufacturing procedures, e.g. accelerated cooling after tempering can induce compressive residual stresses up to about 400 MPa in the hub bore region of turbine disk

  8. Application of laser interferometry for assessment of surface residual stress by determination of stress-free state

    International Nuclear Information System (INIS)

    Kim, Dong Won; Kwon, Dong Il; Lee, Nak Kyu; Choi, Tae Hoon; Na, Kyoung Hoan

    2003-01-01

    The total relaxed stress in annealing and the thermal strain/stress were obtained from the identification of the residual stress-free state using Electronic Speckle Pattern Interferometry (ESPI). The residual stress fields in case of both single and film/substrate systems were modeled using the thermo-elastic theory and the relationship between relaxed stresses and displacements. We mapped the surface residual stress fields on the indented bulk Cu and the 0.5 μm Au film by ESPI. In indented Cu, the normal and shear residual stress are distributed over -1.7 GPa to 700 MPa and -800 GPa to 600 MPa respectively around the indented point and in deposited Au film on Si wafer, the tensile residual stress is uniformly distributed on the Au film from 500 MPa to 800 MPa. Also we measured the residual stress by the X-Ray Diffractometer (XRD) for the verification of above residual stress results by ESPI

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

    Science.gov (United States)

    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. A review of residual stress analysis using thermoelastic techniques

    Energy Technology Data Exchange (ETDEWEB)

    Robinson, A F; Dulieu-Barton, J M; Quinn, S [University of Southampton, School of Engineering Sciences, Highfield, Southampton, SO17 1BJ (United Kingdom); Burguete, R L [Airbus UK Ltd., New Filton House, Filton, Bristol, BS99 7AR (United Kingdom)

    2009-08-01

    Thermoelastic Stress Analysis (TSA) is a full-field technique for experimental stress analysis that is based on infra-red thermography. The technique has proved to be extremely effective for studying elastic stress fields and is now well established. It is based on the measurement of the temperature change that occurs as a result of a stress change. As residual stress is essentially a mean stress it is accepted that the linear form of the TSA relationship cannot be used to evaluate residual stresses. However, there are situations where this linear relationship is not valid or departures in material properties due to manufacturing procedures have enabled evaluations of residual stresses. The purpose of this paper is to review the current status of using a TSA based approach for the evaluation of residual stresses and to provide some examples of where promising results have been obtained.

  11. A review of residual stress analysis using thermoelastic techniques

    International Nuclear Information System (INIS)

    Robinson, A F; Dulieu-Barton, J M; Quinn, S; Burguete, R L

    2009-01-01

    Thermoelastic Stress Analysis (TSA) is a full-field technique for experimental stress analysis that is based on infra-red thermography. The technique has proved to be extremely effective for studying elastic stress fields and is now well established. It is based on the measurement of the temperature change that occurs as a result of a stress change. As residual stress is essentially a mean stress it is accepted that the linear form of the TSA relationship cannot be used to evaluate residual stresses. However, there are situations where this linear relationship is not valid or departures in material properties due to manufacturing procedures have enabled evaluations of residual stresses. The purpose of this paper is to review the current status of using a TSA based approach for the evaluation of residual stresses and to provide some examples of where promising results have been obtained.

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

    International Nuclear Information System (INIS)

    Hempel, Nico; Nitschke-Pagel, Thomas; Dilger, Klaus

    2017-01-01

    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 not 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.

  13. On residual stresses and fatigue of laser hardened steels

    International Nuclear Information System (INIS)

    Lin, Ru.

    1992-01-01

    This thesis deals with studies on residual stresses and fatigue properties of laser-transformation hardened steels. Two types of specimens, cylinders and fatigue specimens were used in the studies. The cylinders, made of Swedish steels SS 2244 and SS 2258 which correspond to AISI 4140 and AISI 52100 respectively, were locally hardened by a single scan of laser beam in the longitudinal direction, with various laser parameters. Residual stress distributions across the hardened tracks were measured by means of X-ray diffraction. The origins of residual stresses were investigated and discussed. For the fatigue specimens, including smooth and notched types made of Swedish steels SS 2244, SS 2225 and SS 1572 (similar to AISI 4140, AISI 4130 and AISI 1035, respectively), laser hardening was carried out in the gauge section. The residual stress field induced by the hardening process and the fatigue properties by plane bending fatigue test were studied. In order to investigate the stability of the residual stress field, stress measurements were also made on specimens being loaded near the fatigue limits for over 10 7 cycles. Further the concept of local fatigue strength was employed to correlate quantitatively the effect of hardness and residual stress field on the fatigue limits. In addition a group of smooth specimens of SS 2244 was induction hardened and the hardening results were compared with the corresponding laser hardened ones in terms of residual stress and fatigue behaviour. It has been found that compressive stresses exist in the hardened zone of all the specimens studied. The laser hardening condition, the specimen and how the hardening is carried out can significantly affect the residual stress field. Laser hardening can greatly improve the fatigue properties by inducing a hardened and compressed surface layer. (112 refs.)(au)

  14. On residual stresses and fatigue of laser hardened steels

    Energy Technology Data Exchange (ETDEWEB)

    Lin, Ru.

    1992-01-01

    This thesis deals with studies on residual stresses and fatigue properties of laser-transformation hardened steels. Two types of specimens, cylinders and fatigue specimens were used in the studies. The cylinders, made of Swedish steels SS 2244 and SS 2258 which correspond to AISI 4140 and AISI 52100 respectively, were locally hardened by a single scan of laser beam in the longitudinal direction, with various laser parameters. Residual stress distributions across the hardened tracks were measured by means of X-ray diffraction. The origins of residual stresses were investigated and discussed. For the fatigue specimens, including smooth and notched types made of Swedish steels SS 2244, SS 2225 and SS 1572 (similar to AISI 4140, AISI 4130 and AISI 1035, respectively), laser hardening was carried out in the gauge section. The residual stress field induced by the hardening process and the fatigue properties by plane bending fatigue test were studied. In order to investigate the stability of the residual stress field, stress measurements were also made on specimens being loaded near the fatigue limits for over 10[sup 7] cycles. Further the concept of local fatigue strength was employed to correlate quantitatively the effect of hardness and residual stress field on the fatigue limits. In addition a group of smooth specimens of SS 2244 was induction hardened and the hardening results were compared with the corresponding laser hardened ones in terms of residual stress and fatigue behaviour. It has been found that compressive stresses exist in the hardened zone of all the specimens studied. The laser hardening condition, the specimen and how the hardening is carried out can significantly affect the residual stress field. Laser hardening can greatly improve the fatigue properties by inducing a hardened and compressed surface layer. (112 refs.)(au).

  15. Residual stress improvement for pipe weld by means of induction heating pre-flawed pipe

    International Nuclear Information System (INIS)

    Umemoto, T.; Yoshida, K.; Okamoto, A.

    1980-01-01

    The intergranular stress corrosion cracking (IGSCC) has been found in type 304 stainless steel piping of several BWR plants. It is already well known that IGSCC is most likely to occur when three essential factors, material sensitization, high tensile stress and corrosive environment, are present. If the welding residual stress is sufficiently high (200 to approximately 400 MPa) in the inside piping surface near the welded joint, then it may be one of the biggest contributors to IGSCC. If the residual stress is reduced or reversed by some way, the IGSCC will be effectively mitigated. In this paper a method to improve the residual stress named IHSI (Induction Heating Stress Improvement) is explained. IHSI aims to improve the condition of residual stress in the inside pipe surface using the thermal stress induced by the temperature difference in pipe wall, that is produced when the pipe is heated from the outside surface by an induction heating coil and cooled on the inside surface by water simultaneously. This method becomes more attractive when it can be successfully applied to in-service piping which might have some pre-flaw. In order to verify the validity of IHSI for such piping, some experiments and calculations using finite element method were conducted. These results are mainly discussed in this paper from the view-points of residual stress, flaw behaviour during IHSI and material deterioration. (author)

  16. Improvement and Validation of Weld Residual Stress Modelling Procedure

    International Nuclear Information System (INIS)

    Zang, Weilin; Gunnars, Jens; Dong, Pingsha; Hong, Jeong K.

    2009-06-01

    The objective of this work is to identify and evaluate improvements for the residual stress modelling procedure currently used in Sweden. There is a growing demand to eliminate any unnecessary conservatism involved in residual stress assumptions. The study was focused on the development and validation of an improved weld residual stress modelling procedure, by taking advantage of the recent advances in residual stress modelling and stress measurement techniques. The major changes applied in the new weld residual stress modelling procedure are: - Improved procedure for heat source calibration based on use of analytical solutions. - Use of an isotropic hardening model where mixed hardening data is not available. - Use of an annealing model for improved simulation of strain relaxation in re-heated material. The new modelling procedure is demonstrated to capture the main characteristics of the through thickness stress distributions by validation to experimental measurements. Three austenitic stainless steel butt-welds cases are analysed, covering a large range of pipe geometries. From the cases it is evident that there can be large differences between the residual stresses predicted using the new procedure, and the earlier procedure or handbook recommendations. Previously recommended profiles could give misleading fracture assessment results. The stress profiles according to the new procedure agree well with the measured data. If data is available then a mixed hardening model should be used

  17. Improvement and Validation of Weld Residual Stress Modelling Procedure

    Energy Technology Data Exchange (ETDEWEB)

    Zang, Weilin; Gunnars, Jens (Inspecta Technology AB, Stockholm (Sweden)); Dong, Pingsha; Hong, Jeong K. (Center for Welded Structures Research, Battelle, Columbus, OH (United States))

    2009-06-15

    The objective of this work is to identify and evaluate improvements for the residual stress modelling procedure currently used in Sweden. There is a growing demand to eliminate any unnecessary conservatism involved in residual stress assumptions. The study was focused on the development and validation of an improved weld residual stress modelling procedure, by taking advantage of the recent advances in residual stress modelling and stress measurement techniques. The major changes applied in the new weld residual stress modelling procedure are: - Improved procedure for heat source calibration based on use of analytical solutions. - Use of an isotropic hardening model where mixed hardening data is not available. - Use of an annealing model for improved simulation of strain relaxation in re-heated material. The new modelling procedure is demonstrated to capture the main characteristics of the through thickness stress distributions by validation to experimental measurements. Three austenitic stainless steel butt-welds cases are analysed, covering a large range of pipe geometries. From the cases it is evident that there can be large differences between the residual stresses predicted using the new procedure, and the earlier procedure or handbook recommendations. Previously recommended profiles could give misleading fracture assessment results. The stress profiles according to the new procedure agree well with the measured data. If data is available then a mixed hardening model should be used

  18. Residual stress behaviors induced by laser peening along the edge of curved models

    International Nuclear Information System (INIS)

    Im, Jong Bin; Grandhi, Ramana V.; Ro, Young Hee

    2012-01-01

    Laser peening (LP) induces high magnitude compressive residual stresses in a small region of a component. The compressive residual stresses cause plastic deformation that is resistant to fatigue fracture. Fatigue cracks are generally nucleated at critical areas, and LP is applied for those regions so as to delay the crack initiation. Many critical regions are located on the edge of the curved portion of structures because of stress concentration effects. Several investigations that are available for straight components may not give meaningful guidelines for peening curved components. Therefore, in this paper, we investigate residual stress behaviors induced by LP along the edge of curved models. Three curved models that have different curvatures are investigated for peening performance. Two types of peening configurations, which are simultaneous corner shot and sequential corner shots, are considered in order to obtain compressive residual stresses along an edge. LP simulations of multiple shots are performed to identify overlapping effects on the edge portion of a curved model. In addition, the uncertainty calculation of residual stress induced by LP considering laser pulse duration is performed

  19. Sensitivity Analysis for Residual Stress on DVI (Direct Vessel Injection) Nozzle Welded Joint

    International Nuclear Information System (INIS)

    Noh, Byeong Wook; Chung, Sung Ho; Lee, Jung Hun; Kim, Oak Sug

    2008-01-01

    Generally, any welding process produces high compressive or tensile residual stresses in the heat affected zone depending on the method, shape and procedures of the weldment. In particular, the tensile residual stresses have a considerable effect on the material strength, fatigue strength and corrosion cracking. For this reason, it is important that some knowledge of the internal stress state be deduced either from measurements or from modeling predictions. In this study, the residual stresses after a multi-pass welding process for DVI nozzle welding joint were evaluated by a numerical simulation method. The welding joint considered three weld joint angles of 40 deg., 6 deg. and 2 deg. Computations were made using a 2-D finite element model based on the simulation of cooling from the heat treatment temperature to room temperature with two cooling conditions at the inside surface. In these results, it is shown that the residual stress increased at the inner surface, when water cooling was applied to the inner surface, and axial compressive residual stress increased at the inner surface when the joint angle was decreased. (authors)

  20. Sensitivity Analysis for Residual Stress on DVI (Direct Vessel Injection) Nozzle Welded Joint

    Energy Technology Data Exchange (ETDEWEB)

    Noh, Byeong Wook; Chung, Sung Ho; Lee, Jung Hun; Kim, Oak Sug [DOOSAN Heavy Industries and Construction Co. LTD, Reactor Design Team, 555 Guygok-dong Changwon (Korea, Republic of)

    2008-07-01

    Generally, any welding process produces high compressive or tensile residual stresses in the heat affected zone depending on the method, shape and procedures of the weldment. In particular, the tensile residual stresses have a considerable effect on the material strength, fatigue strength and corrosion cracking. For this reason, it is important that some knowledge of the internal stress state be deduced either from measurements or from modeling predictions. In this study, the residual stresses after a multi-pass welding process for DVI nozzle welding joint were evaluated by a numerical simulation method. The welding joint considered three weld joint angles of 40 deg., 6 deg. and 2 deg. Computations were made using a 2-D finite element model based on the simulation of cooling from the heat treatment temperature to room temperature with two cooling conditions at the inside surface. In these results, it is shown that the residual stress increased at the inner surface, when water cooling was applied to the inner surface, and axial compressive residual stress increased at the inner surface when the joint angle was decreased. (authors)

  1. Evaluation of residual stresses for the multipass welds of 316L stainless steel pipe

    International Nuclear Information System (INIS)

    Kim, S. H.; Joo, Y. S.; Lee, J. H.

    2003-01-01

    It is necessary to evaluate the influence of the residual stress and distortion in the design and fabrication of welded structure and the sound welded structure can be maintained by this consideration. Multipass welds of the 316L stainless steel have been widely employed in the pipes of Liquid Metal Reactor. In this study, the residual stresses in the 316L stainless steel pipe welds were calculated by the finite element method using ANSYS code. Also, the residual stresses both on the surface and in the interior of the thickness were measured by HRPD(High Resolution Powder Diffractometer) instrumented in HANARO Reactor. The residual stresses were measured for each 18 points in small(t/d=0.075) and large pipe specimens (t/d=0.034). The experimental and calculated results were compared and the characteristics of the distribution of the residual stress discussed

  2. Nonlinear morphoelastic plates I: Genesis of residual stress

    KAUST Repository

    McMahon, J.

    2011-04-28

    Volumetric growth of an elastic body may give rise to residual stress. Here a rigorous analysis is given of the residual strains and stresses generated by growth in the axisymmetric Kirchhoff plate. Balance equations are derived via the Global Constraint Principle, growth is incorporated via a multiplicative decomposition of the deformation gradient, and the system is closed by a response function. The particular case of a compressible neo-Hookean material is analyzed, and the existence of residually stressed states is established. © SAGE Publications 2011.

  3. Nonlinear morphoelastic plates I: Genesis of residual stress

    KAUST Repository

    McMahon, J.; Goriely, A.; Tabor, M.

    2011-01-01

    Volumetric growth of an elastic body may give rise to residual stress. Here a rigorous analysis is given of the residual strains and stresses generated by growth in the axisymmetric Kirchhoff plate. Balance equations are derived via the Global Constraint Principle, growth is incorporated via a multiplicative decomposition of the deformation gradient, and the system is closed by a response function. The particular case of a compressible neo-Hookean material is analyzed, and the existence of residually stressed states is established. © SAGE Publications 2011.

  4. Residual stress characterization of welds using x-ray diffraction techniques

    International Nuclear Information System (INIS)

    Pineault, J.A.; Brauss, M.E.

    1996-01-01

    Neglect of residual stresses created during processes lead to stress corrosion cracking, distortion, fatigue cracking, premature failures in components, and instances of over design. Automated residual stress mapping and truly portable equipment have now made the characterization of residual stresses using x-ray diffraction (XRI) practical. The nondestructive nature of the x-ray diffraction technique has made the tile residual stress characterization of welds a useful tool for process optimization and failure analysis, particularly since components can be measured before and after welding and post welding processes. This paper illustrates the importance of residual stress characterization in welds and presents examples where x-ray diffraction techniques were applied in the characterization of various kinds of welds. arc welds, TIG welds, resistance welds, laser welds and electron beam welds. Numerous techniques are available to help manage potentially harmfull residual stresses created during the welding process thus, the effects of a few example post weld processes such as grinding, heat treating and shot peening are also addressed

  5. A proposed residual stress model for oblique turning

    International Nuclear Information System (INIS)

    Elkhabeery, M. M.

    2001-01-01

    A proposed mathematical model is presented for predicting the residual stresses caused by turning. Effects of change in tool free length, cutting speed, feed rate, and the tensile strength of work piece material on the maximum residual stress are investigated. The residual stress distribution in the surface region due to turning under unlubricated condition is determined using a deflection etching technique. To reduce the number of experiments required and build the mathematical model for these variables, Response Surface Methodology (RSM) is used. In addition, variance analysis and an experimental check are conducted to determine the prominent parameters and the adequacy of the model. The results show that the tensile stress of the work piece material, cutting speed, and feed rate have significant effects on the maximum residual stresses. The proposed model, that offering good correlation between the experimental and predicted results, is useful in selecting suitable cutting parameters for the machining of different materials. (author)

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

    Science.gov (United States)

    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.

  7. A Numerical Model for Prediction of Residual Stress Using Rayleigh Waves

    International Nuclear Information System (INIS)

    Yuan, Mao Dan; Kang, To; Kim, Hak Joon; Song, Sung Jin

    2011-01-01

    In this work, a numerical model is proposed for the relation between the magnitudes and the depth residual stress with the velocity of Rayleigh wave. Three cases, stress-free, uniform stress and layered stress, are investigated for the change tendency of the Rayleigh wave speed. Using the simulated signal with variation of residual stress magnitude and depth, investigation of the parameters for fitting residual stress and velocity change are performed. The speed change of Rayleigh wave shows a linear relation with the magnitude and an exponential relation with the depth of residual stress. The combination of these two effects could be used for the depth profile evaluation of the residual stress

  8. Residual stresses in plastic random systems

    NARCIS (Netherlands)

    Alava, M.J.; Karttunen, M.E.J.; Niskanen, K.J.

    1995-01-01

    We show that yielding in elastic plastic materials creates residual stresses when local disorder is present. The intensity of these stresses grows with the external stress and degree of initial disorder. The one-dimensional model we employ also yields a discontinuous transition to perfect plasticity

  9. Estimation of stress intensity factors for circumferential cracked pipes under welding residual stress filed

    International Nuclear Information System (INIS)

    Oh, Chang Young; Kim, Yun Jae; Oh, Young Jin; Song, Tae Kwang; Kim, Yong Beum; Oh, Young Jin; Song, Tae Kwang; Kim, Yong Beum

    2012-01-01

    Recently, stress corrosion cracking(SCC) have been found in dissimilar metal welds of nozzles in some pressurized water reactors and on low carbon stainless steel piping systems of boiling water reactors. The important factor of SCC is the residual stress field caused by weld. For the evaluation of crack growth analysis due to SCC, stress intensity factor under a residual stress field should be estimated. Several solutions for stress intensity factor under residual stress field were recommended in flaw assessment codes such as the American Society of Mechanical Engineers (ASME) Section XI, R6, American Petroleum Institute (API579). Some relevant works have been studied. Dong et al. evaluated stress intensity factors in welded structures. Miyazaki et al. estimated stress intensity factors of surface crack in simple stress fields. This paper presents a simple method to estimate stress intensity factors in welding residual stress field. For general application, results of structure integrity assessment codes KI solutions were compared Finite element analyses of welding simulation and cracked pipes are described. Comparison results of KI solutions and proposed simplified solution are presented in the works

  10. Analytical and Experimental Study of Residual Stresses in CFRP

    Directory of Open Access Journals (Sweden)

    Chia-Chin Chiang

    2013-01-01

    Full Text Available Fiber Bragg Grating sensors (FBGs have been utilized in various engineering and photoelectric fields because of their good environment tolerance. In this research, residual stresses of carbon fiber reinforced polymer composites (CFRP were studied using both experimental and analytical approach. The FBGs were embedded inside middle layers of CFRP to study the formation of residual stress during curing process. Finite element analysis was performed using ABAQUS software to simulate the CFRP curing process. Both experimental and simulation results showed that the residual stress appeared during cooling process and the residual stresses could be released when the CFRP was machined to a different shape.

  11. Methods of measuring residual stresses in components

    International Nuclear Information System (INIS)

    Rossini, N.S.; Dassisti, M.; Benyounis, K.Y.; Olabi, A.G.

    2012-01-01

    Highlights: ► Defining the different methods of measuring residual stresses in manufactured components. ► Comprehensive study on the hole drilling, neutron diffraction and other techniques. ► Evaluating advantage and disadvantage of each method. ► Advising the reader with the appropriate method to use. -- Abstract: Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components. Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non-destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments.

  12. Measurement of residual stresses by the moire method

    Science.gov (United States)

    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.

  13. Residual stress distribution analysis of heat treated APS TBC using image based modelling.

    Science.gov (United States)

    Li, Chun; Zhang, Xun; Chen, Ying; Carr, James; Jacques, Simon; Behnsen, Julia; di Michiel, Marco; Xiao, Ping; Cernik, Robert

    2017-08-01

    We carried out a residual stress distribution analysis in a APS TBC throughout the depth of the coatings. The samples were heat treated at 1150 °C for 190 h and the data analysis used image based modelling based on the real 3D images measured by Computed Tomography (CT). The stress distribution in several 2D slices from the 3D model is included in this paper as well as the stress distribution along several paths shown on the slices. Our analysis can explain the occurrence of the "jump" features near the interface between the top coat and the bond coat. These features in the residual stress distribution trend were measured (as a function of depth) by high-energy synchrotron XRD (as shown in our related research article entitled 'Understanding the Residual Stress Distribution through the Thickness of Atmosphere Plasma Sprayed (APS) Thermal Barrier Coatings (TBCs) by high energy Synchrotron XRD; Digital Image Correlation (DIC) and Image Based Modelling') (Li et al., 2017) [1].

  14. Residual stress analysis of drive shafts after induction hardening

    Energy Technology Data Exchange (ETDEWEB)

    Lemos, Guilherme Vieira Braga; Rocha, Alexandre da Silva; Nunes, Rafael Menezes, E-mail: lemos_gl@yahoo.com.br [Universidade Federal do Rio Grande do Sul (UFRS), Porto Algre, RS (Brazil); Hirsch, Thomas Karl [Stiftung Institut für Werkstofftechnik (IWT), Bremen (Germany)

    2014-08-15

    Typically, for automotive shafts, shape distortion manifests itself in most cases after the induction hardening by an effect known as bending. The distortion results in a boost of costs, especially due to machining parts in the hardened state to fabricate its final tolerances. In the present study, residual stress measurements were carried out on automotive drive shafts made of DIN 38B3 steel. The samples were selected in consequence of their different distortion properties by an industrial manufacturing line. One tested shaft was straightened, because of the considerable dimensional variation and the other one not. Firstly, the residual stress measurements were carried out by using a portable diffractometer, in order to avoid cutting the shafts and evaluate the original state of the stresses, and afterwards a more detailed analysis was realized by a conventional stationary diffractometer. The obtained results presented an overview of the surface residual stress profiles after induction hardening and displayed the influence of the straightening process on the redistribution of residual stresses. They also indicated that the effects of the straightening in the residual stresses cannot be neglected. (author)

  15. Finite Element Residual Stress Analysis of Planetary Gear Tooth

    Directory of Open Access Journals (Sweden)

    Jungang Wang

    2013-01-01

    Full Text Available A method to simulate residual stress field of planetary gear is proposed. In this method, the finite element model of planetary gear is established and divided to tooth zone and profile zone, whose different temperature field is set. The gear's residual stress simulation is realized by the thermal compression stress generated by the temperature difference. Based on the simulation, the finite element model of planetary gear train is established, the dynamic meshing process is simulated, and influence of residual stress on equivalent stress of addendum, pitch circle, and dedendum of internal and external meshing planetary gear tooth profile is analyzed, according to non-linear contact theory, thermodynamic theory, and finite element theory. The results show that the equivalent stresses of planetary gear at both meshing and nonmeshing surface are significantly and differently reduced by residual stress. The study benefits fatigue cracking analysis and dynamic optimization design of planetary gear train.

  16. Residual stress analysis in carbon fiber-reinforced SiC ceramics

    International Nuclear Information System (INIS)

    Broda, M.

    1998-01-01

    Systematic residual stress analyses are reported, carried out in long-fiber reinforced SiC ceramics. The laminated C fiber /SiC matrix specimens used were prepared by polymer pyrolysis, and the structural component specimens used are industrial products. Various diffraction methods have been applied for non-destructive evaluation of residual stress fields, so as to completely detect the residual stresses and their distribution in the specimens. The residual stress fields at the surface (μm) have been measured using characteristic X-radiation and applying the sin 2 ψ method as well as the scatter vector method. For residual stress field analysis in the mass volume (cm), neutron diffraction has been applied. The stress fields in the fiber layers (approx. 250μm) have been measured as a function of their location within the laminated composite by using an energy-dispersive method and synchrotron radiation. By means of the systematic, process-accompanying residual stress and phase analyses, conclusions can be drawn as to possible approaches for optimization of fabrication parameters. (orig./CB) [de

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

    Science.gov (United States)

    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.

  18. Measurement of residual stress in plasma-sprayed metallic, ceramic and composite coatings

    Energy Technology Data Exchange (ETDEWEB)

    Kesler, O.; Suresh, S. [Massachusetts Inst. of Tech., Cambridge, MA (United States); Matejicek, J.; Sampath, S. [State Univ. of New York, Stony Brook, NY (United States). Inst. for Mathematical Sciences; Gnaeupel-Herold, T.; Brand, P.C.; Prask, H.J. [National Institute of Standards and Technology, Gaithersburg, MD (United States)

    1998-12-15

    Residual stresses in plasma-sprayed coatings were studied by three experimental techniques: curvature measurements, neutron diffraction and X-ray diffraction. Two distinct material classes were investigated: (1) single-material coatings (molybdenum) and (2) bi-material composites (nickel+alumina and NiCrAlY+yttria-stabilized zirconia), with and without graded layers. This paper deals with the effects of coating thickness and material properties on the evolution of residual stresses as a function of composition and thickness in both homogeneous and graded coatings. Mathematical analysis of the results allowed in some cases the separation of the quenching stress and thermal stress contributions to the final residual stress, as well as the determination of the through-thickness stress profile from measurements of different thickness specimens. In the ceramic-metal composites, it was found that the quenching stress plays a dominant role in the metallic phase, whereas the stress in the ceramic phase is mostly dominated by thermal mismatch. The respective thermal expansion coefficients and mechanical properties are the most important factors determining the stress sign and magnitude. The three residual stress measurement methods employed here were found to be complementary, in that each can provide unique information about the stress state. The most noteworthy outcomes are the determination of the through-thickness stress profile in graded coatings with high spatial resolution (curvature method) and determination of stress in each phase of a composite separately (neutron diffraction). (orig.) 25 refs.

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

    International Nuclear Information System (INIS)

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

    2017-01-01

    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. (paper)

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

    Science.gov (United States)

    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.

  1. Residual stresses due to weld repairs, cladding and electron beam welds and effect of residual stresses on fracture behavior. Annual report, September 1, 1977--November 30, 1978

    International Nuclear Information System (INIS)

    Rybicki, E.F.

    1978-11-01

    The study is divided into three tasks. Task I is concerned with predicting and understanding the effects of residual stresses due to weld repairs of pressure vessels. Task II examines residual stresses due to an electron beam weld. Task III addresses the problem of residual stresses produced by weld cladding at a nozzle vessel intersection. The objective of Task I is to develop a computational model for predicting residual stress states due to a weld repair of pressure vessel and thereby gain an understanding of the mechanisms involved in the creation of the residual stresses. Experimental data from the Heavy Section Steel Technology (HSST) program at Oak Ridge National Laboratories (ORNL) is used to validate the computational model. In Task II, the residual stress model is applied to the case of an electron beam weld of a compact tension freacture specimen. The results in the form of residual stresses near the weld are then used to explain unexpected fracture behavior which is observed in the testing of the specimen. For Task III, the residual stress model is applied to the cladding process used in nozzle regions of nuclear pressure vessels. The residual stresses obtained from this analysis are evaluated to determine their effect on the phenomena of under-clad cracking

  2. Residual stresses analysis in ball end milling of nickel-based superalloy Inconel 718

    Energy Technology Data Exchange (ETDEWEB)

    Wang, Junteng; Zhang, Dinghua; Wu, Baohai; Luo, Ming [Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Northwestern Polytechnical University (China)

    2017-11-15

    Inconel 718 is widely used in the aviation, space, automotive and biomedical industries because of its outstanding properties. Near-surface residual stresses that are induced by ball end milling in Inconel 718 can be crucial for the performance and service time of the machined parts. In this paper, the influences of cutting conditions, including the use of cutting parameters, cutting fluid and spindle angles, on the residual stresses in the ball end milling process of Inconel 718 alloy were investigated experimentally. X-ray diffraction measurements reveal that residual stress distributions are highly influenced by cutting parameters, especially the depth of cut and cutting speed. The milling operation with cooling induces more compressive stresses trend and the magnitude of the residual stresses increases in the tensile direction with the increase of spindle angles. These cutting induced effects were further discussed with respect to thermal- mechanical coupling theory and some observations made by optical microscopy. From this investigation, it is suggested that the machining process parameters are not the smaller the better for the control of residual stresses in the ball end milling process of Inconel 718. (author)

  3. Residual Stresses and Other Properties of Teardrops

    Energy Technology Data Exchange (ETDEWEB)

    Stroud, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Veirs, Douglas Kirk [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Berg, John M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Hill, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Rios, Daniel [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Duque, Juan [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-07-26

    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 factors 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.

  4. Near-surface residual stresses and microstructural changes after turning of a nickel-based superalloy

    Energy Technology Data Exchange (ETDEWEB)

    Schlauer, Christian

    2003-07-01

    Nickel-based superalloys are precipitation hardened alloys with complex compositions. They are used in aircraft engines and land-based gas turbines in load bearing structural components that are exposed to high temperatures. Failure mechanisms in this environment are high and low cycle fatigue, creep, and corrosion. During manufacturing, residual stresses are often introduced into the material due to inhomogeneous plastic deformations, both intentionally and unintentionally. One such manufacturing process is metal cutting, which introduces residual stresses in the surface layer. The stress state in the near-surface zone of components is of special interest as the surface often experiences peak loads and cracks have their starting point there. In this thesis, near-surface residual stress distributions and microstructural changes are studied in the nickel-based superalloy Inconel 718 for two different turning operations, face grooving and facing. Process variables are in both cases cutting speed and feed that have been varied between (10 and 1200) m/min and (0.01 and 0.5) mm, respectively. The first turning technique face grooving, which gives cutting conditions similar to orthogonal cutting, showed a clear dependency of the residual stresses on the cutting speed. The tensile stress at the surface, the maximum compressive stress below the surface, and the thickness of the affected layer increase with increasing cutting speed. The tensile stresses are constrained to a thin surface layer and compressive residual stresses below the surface dominate the depth profile of the residual stresses. Only at low cutting speed, residual stresses were largely avoided. The second turning technique facing confirmed the dependency of the residual stresses on the cutting speed and revealed a similar dependency on the feed. Microstructural investigations of near-surface cross-sections by means of transmission electron microscopy showed a zone where the grains had undergone plastic

  5. Depth-resolved X-ray residual stress analysis in PVD (Ti, Cr) N hard coatings

    CERN Document Server

    Genzel, C

    2003-01-01

    Physical vapour deposition (PVD) of thin hard coatings on TiN basis is usually performed at rather low temperatures (T sub D < 500 C) far from thermal equilibrium, which leads to high intrinsic residual stresses in the growing film. In contrast to the extrinsic thermal residual stresses which can easily be estimated from the difference of the coefficients of thermal expansion between the substrate and the coating, a theoretical prediction of the intrinsic residual stresses is difficult, because their amount as well as their distribution within the film depend in a very complex way on the deposition kinetics. By the example of strongly fibre-textured PVD (Ti, Cr)N coatings which have been prepared under defined variation of the deposition parameters in order to adjust the residual stress distribution within the coatings, the paper compares different X-ray diffraction techniques with respect to their applicability for detecting residual stresses which are non-uniform over the coating thickness. (orig.)

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

    Science.gov (United States)

    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.

  7. Measurement of residual stress in plasma-sprayed composite coatings with graded and uniform compositions

    Energy Technology Data Exchange (ETDEWEB)

    Kesler, O.; Suresh, S. [Massachusetts Inst. of Tech., Cambridge, MA (United States); Matejicek, J.; Sampath, S.

    1999-10-01

    Residual stresses in plasma sprayed composite coatings were studied experimentally by both curvature and neutron diffraction measurements. Graded and uniform composite coatings, consisting of nickel + alumina and NiCrAlY + yttria-stabilized zirconia, were investigated. This paper briefly summarizes our recent work dealing with the effects of coating thickness, composition, and material properties on the evolution of residual stresses in coatings. Analysis of the results allowed in some cases the separation of the quenching stress and thermal stress contributions to the final residual stress, as well as the determination of the through-thickness stress profile from measurements of different thickness specimens. In the ceramic-metal composites, it was found that the thermal mismatch stress plays a dominant role in the ceramic phase, whereas the stress in the metallic phase is mostly dominated by quenching stress. The residual stress measurement methods employed here were found to be complementary, in that each can provide unique information about the stress state. Through-thickness stress profiles in graded coatings were determined with high spatial resolution by the curvature method, and determination of the stress in each separate phase of a composite was made by neutron diffraction. (orig.) 14 refs.

  8. Relationship between ultrasonic Rayleigh waves and surface residual stress

    International Nuclear Information System (INIS)

    Adler, L.; Cook, K.V.; Dewey, B.R.; King, R.T.

    1977-01-01

    Local variations of Rayleigh (surface) circumferential ultrasonic wave velocity near a pipe-girth weld in large-diameter thin-wall type 316H stainless steel pipe were measured. The weldment was similar to those anticipated for the Liquid Metal Fast Breeder Reactor (LMFBR) piping systems. The residual stress distribution was estimated independently from shell theory for an elastic, infinite, thin shell with circumferential line loading. An upper bound on the magnitude of the residual stresses was estimated assuming the deformation of the shell was entirely elastic. The pattern of surface wave velocity variations matches the theoretical residual stress pattern closely. It is suggested that the monitoring of surface wave velocity variations might be used for characterizing residual stress patterns near critical welds in piping, aiding in design calculations, and for in-service monitoring of the state of stress of weldments

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

    Science.gov (United States)

    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.

  10. Prediction of retained residual stresses in laboratory fracture mechanics specimens extracted from welded components

    International Nuclear Information System (INIS)

    Hurlston, R.G.; Sherry, A.H.; James, P.; Sharples, J.K.

    2015-01-01

    The measurement of weld material fracture toughness properties is important for the structural integrity assessment of engineering components. However, welds can contain high levels of residual stress and these can be retained in fracture mechanics specimens, particularly when machined from non-stress relieved welds. Retained residual stresses can make the measurement of valid fracture toughness properties difficult. This paper describes the results of analytical work undertaken to investigate factors that can influence the magnitude and distribution of residual stresses retained in fracture mechanics specimen blanks extracted from as-welded ferritic and austenitic stainless steel plates. The results indicate that significant levels of residual stress can be retained in specimen blanks prior to notching, and that the magnitude and distribution of stress is dependent upon material properties, specimen geometry and size, and extraction location through the thickness of the weld. Finite element modelling is shown to provide a useful approach for estimating the level and distributions of retained residual stresses. A new stress partitioning approach has been developed to estimate retained stress levels and results compare favourably with FE analysis and available experimental data. The approach can help guide the selection of specimen geometry and machining strategies to minimise the level of residual stresses retained in fracture mechanics specimen blanks extracted from non stress-relieved welds and thus improve the measurement of weld fracture toughness properties. - Highlights: • A simplified method for generating realistic weld residual stresses has been developed. • It has been shown that significant levels of residual stress can be retained within laboratory fracture mechanics specimens. • The level and distribution is dependant upon material, specimen type, specimen size and extraction location. • A method has been developed to allow estimates of the

  11. Investigation of residual stress in laser welding dissimilar materials

    International Nuclear Information System (INIS)

    Mirim, Denilson de Camargo; Oliveira, Rene Ramos de; Berretta, Jose Roberto; Rossi, Wagner de; Lima, Nelson Batista de; Delijaicov, Sergio; Gomes, Diego Oliva

    2010-01-01

    One of the most critical problems found in the different materials welding is the residual stress formation, that happens mainly for the fact of those materials they possess coefficients of thermal expansion and different thermal conductivities. Like this in this work the residual tension was evaluated in the technique of welding laser among the steel low carbon, AISI 1010 and AISI 304. The materials were united for it welds autogenous of top with a laser of continuous Nd:YAG in that they were varied the potency, speed and the focus of the laser stayed constant in relation to surface of the sample. The main objective of the study went identification and to analysis of the residual stress in HAZ on both sides of seem. Um planning factorial of two factors at two levels each it was executed for optimization the combination of the factors potency and speed. The obtained answers were the residual stress in different depths in HAZ. In the surface of the sample measures of residual stress were accomplished by the technique of X-ray diffraction. The hole drilling strain gage method it was applied to measure the residual stress on both sides of the union. The results were analyzed using the variance analysis and the statistical regression based on the different influences of the entrance and combination of the factors in the residual stress generated in that union. The results indicate that the development of models can foresee the answers satisfactorily. (author)

  12. Residual stress effects on the K parameter of the fracture mechanics

    International Nuclear Information System (INIS)

    Soares, Maria da Conceiccao B. Vieira; Andrade, Arnaldo H. Paes de

    1996-01-01

    Compressive residual stresses are beneficial and improve resistance to fracture and crack growth. Residual stresses can be introduced in fabricated components by a variety of means and a number of methods such as laser surface treatment, cold expanded hole, and shot peening. Neutrons diffraction measurements of residual stress were performed at a pulsed neutron source (ISIS, Didcot, UK), on shot peened plates of nickel base superalloy Udimet 720 and titanium alloy IMI 834. The stress intensity factor (K) of residual stress was evaluated by finite element modeling and weight function method. Finite element modeling of a 2D plate with a single edge-notch was applied and, due to symmetry only half of the plate was actually modeled. The stress intensity factor (K) was evaluated for both case of remote tension stress and residual stress. Crack surface overlapping, which is physically unacceptable, was noted for small cracks under residual and boundary lading. Overlap correction was proposed and applied in order to obtain reliable values for (K). (author)

  13. Residual stresses and stress corrosion effects in cast steel nuclear waste overpacks

    International Nuclear Information System (INIS)

    Attinger, R.O.; Mercier, O.; Knecht, B.; Rosselet, A.; Simpson, J.P.

    1991-01-01

    In the concepts for final disposal of high-level radioactive waste in Switzerland, one engineered barrier consists of an overpack made out of cast steel GS-40. Whenever tensile stresses are expected in the overpack, the issue of stress corrosion cracking must be expected. A low-strength steel was chosen to minimize potential problems associated with stress corrosion cracking. A series of measurements on stress corrosion cracking under the conditions as expected in the repository confirmed that the corrosion allowance of 50 mm used for the design of the reference overpack is sufficient over the 1000 years design lifetime. Tensile stresses are introduced by the welding process when the overpack is closed. For a multipass welding, the evolution of deformations, strains and stresses were determined in a finite-element calculation. Assuming an elastic-plastic material behavior without creep, the residual stresses are high; considering creep would reduce them. A series of creep tests revealed that the initial creep rate is important for cast steel already at 400deg C. (orig.)

  14. Residual stress analysis for engineering applications by means of neutron diffraction

    International Nuclear Information System (INIS)

    Gnaeupel-Herold, T.; Brand, P.C.; Prask, H.J.

    1999-01-01

    Residual stresses originate from spatial differences in plastic deformation, temperature, or phase distribution, introduced by manufacturing processes or during service. Engineering parts and materials experience mechanical, thermal, and chemical loads during their service, and most of these loads introduce stresses that are superimposed on the already existing residual stresses. Residual stresses can therefore limit or improve life and strength of engineering parts; knowledge and understanding of these stresses is therefore critical for optimizing strength and durability. The economic and scientific importance of neutron diffraction residual stress analysis has led to an increasing number of suitable instruments worldwide. All of the major sources due in the next several years will have instruments for the sole purpose of performing residual stress and texture measurements. Recently, a dedicated, state-of-the-art diffractometer has been installed at the National Institute of Standards and Technology reactor. It has been used for a variety of measurements on basic and engineering stress problems. Among the most prominent examples that have been investigated in collaboration with industrial and academic partners are residual stresses in rails, weldments, and plasma-sprayed coatings

  15. Residual stress relief in MAG welded joints of dissimilar steels

    International Nuclear Information System (INIS)

    Seodek, P.; Brozda, J.; Wang, L.; Withers, P.J.

    2003-01-01

    This paper addresses the relief of residual stress in welded joints between austenitic and non-alloyed ferritic-pearlitic steels. A series of similar and dissimilar steel joints based on the 18G2A (ferritic-pearlitic) and 1H18N10T (austenitic) steels were produced, some of which were stress relieved by annealing and some by mechanical prestressing. For the as-welded and stress relieved test joints the residual stresses were measured by trepanning. To aid the interpretation of these results, 2D plane stress finite element analysis has been performed to simulate the residual stress relieving methods. Analysis of the results has shown that thermal stress relieving of welded joints between dissimilar steels is not effective and may even increase residual stresses, due to the considerable difference in thermal expansion of the joined steels. It was found that, for the loads imposed, the effectiveness of the mechanical stress relieving of dissimilar steel welded joints was much lower than that of similar steel joints

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

    Science.gov (United States)

    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.

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

    Directory of Open Access Journals (Sweden)

    E. Hristoforou

    2018-04-01

    Full Text Available 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.

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

    Science.gov (United States)

    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.

  19. Prediction of three-dimensional residual stresses at localised indentations in pipes

    International Nuclear Information System (INIS)

    Hyde, T.H.; Luo, R.; Becker, A.A.

    2012-01-01

    Residual stresses are investigated using Finite Element (FE) analyses at localised indentations in pipes with and without internal pressures due to reverse plasticity caused by springback of the surrounding material after removal of the indenter. The indentation loading is applied via rigid 3D short indenters. The effects of the residual indentation depth, internal pressure, indenter size and different material properties on the residual stresses for different pipes have been investigated by carrying out parametric sensitivity studies. In order to predict the residual stresses, empirical formulations have been developed, which show a good correlation with the FE for residual stresses for pipes with diameter to thickness ratios of 35–72. - Highlights: ► A comprehensive elastic–plastic FE analysis of residual stresses caused by localised pipe indentations is presented. ► The effects of residual indentation depth, internal pressure, indenter size and material properties have been studied. ► Empirical formulations have been developed, which show a good correlation with the FE for residual stresses for pipes with diameter to thickness ratios of 35–72.

  20. Reduction method for residual stress of welded joint using random vibration

    International Nuclear Information System (INIS)

    Aoki, Shigeru; Nishimura, Tadashi; Hiroi, Tetsumaro

    2005-01-01

    Welded joints are used for construction of many structures. Residual stress is induced near the bead caused by locally given heat. Tensile residual stress on the surface may reduce fatigue strength. In this paper, a new method for reduction of residual stress using vibration during welding is proposed. As vibrational load, random vibration, white noise and filtered white noise are used. Two thin plates are butt-welded. Residual stress is measured with a paralleled beam X-ray diffractometer with scintillation counter after removing quenched scale chemically. It is concluded that tensile residual stress near the bead is reduced by using random vibration during welding

  1. Residual stress evaluation by neutron and synchrotron radiation

    International Nuclear Information System (INIS)

    Lodini, A.

    2000-01-01

    This lecture is dedicated to the residual stress evaluation using neutron and X ray synchrotron radiation. Residual stress evaluation is an important step for the improvement or the performance of materials, the control of the deformation of the components and the understanding of industrial process. In general, residual stress has various origins: mechanical, thermal, thermomechanical or thermochemical. In general, these residual stresses are caused by plastic deformation, or some source of local incompatibilities and are generated by three fundamental physical origins: plastic flow, volume change and thermal dilatation. These incompatibilities are compensated for partly by the elastic deformation that generates some internal stresses. In the solid, these local incompatibilities are caused by crystal defects. The exact origin of a stress is going to depend on the scale of observation. A classification of the residual stresses in three orders, related to the scale on which one considers materials, is proposed. The diffraction method for determination of macrostresses is based on the measurement of interplanar spacing for various direction in a diffraction experiment. Different examples are proposed. Polycrystalline grains or composite have different physical and elastic properties hence the stress for a particular grains or phase differs from the average value (value of macrostress). This difference is defined as the second order stress. The second order stresses occur because of small scale anisotropy or inhomogeneity in the material : for example, due to mismatch in coefficient of thermal expansion, elastic constants or plastic flow. However, the second order stress averaged over all grains or phase is not equal to zero and this average is called the mismatch stress. Using the experimental macro stress it is possible to calculate the mismatch stresses. More recently, this technique of diffraction has also been applied for the determination of microstrain (third

  2. Fatigue life estimation considering welding residual stress and hot-spot stress of welded components

    International Nuclear Information System (INIS)

    Han, S. H.; Lee, T. K.; Shin, B. C.

    2002-01-01

    The fatigue life of welded joints is sensitive to welding residual stress and complexity of their geometric shapes. To predict the fatigue life more reasonably, the effects of welding residual stress and its relaxation have to be considered quantitatively which are equivalent to mean stress by external loads. The hot-spot stress concept should be also adopted which can be reduce the dependence of fatigue strengths for various welding details. Considering the factors mentioned above, a fatigue life prediction model using the modified Goodman's diagram was proposed. In this model, an equivalent stress was introduced which are composed of the mean stress based on the hot-spot stress concept and the relaxed welding residual stress. From the verification of the proposed model to real welding details, it is confirmed that this model can be applied to predict reasonably their fatigue lives

  3. Forging And Milling Contribution On Residual Stresses For A Textured Biphasic Titanium Alloy

    International Nuclear Information System (INIS)

    Deleuze, C.; Fabre, A.; Barrallier, L.; Molinas, O.

    2011-01-01

    Ti-10V-2Fe-3Al is a biphasic titanium alloy (α+β) used in aeronautical applications for its mechanical properties, such as its yield strength of 1200 MPa and it weighs 40% less than steel. This alloy is particularly useful for vital parts with complex geometry, because of its high forging capability. In order to predict the capability for fatigue lifetime, the designers need to know the residual stresses. X-Ray diffraction is the main experimental technique used to determine residual stresses on the surface. In this case, stress levels are primarily influenced by the complex forging and milling process. On this alloy in particular, it may be difficult to characterize stress due to modification of the microstructure close to the surface. Results obtained by x-ray analysis depend on the correct definition of the shape of the diffraction peaks. The more precisely defined the position of the peak, the more accurately the stresses are evaluated. This paper presents a method to detect if residual stresses can be characterized by x-ray diffraction. The characterization of hardness seems to be a relevant technique to quickly analyze the capability of x-ray diffraction to determine residual stresses.

  4. Residual Stresses In 3013 Containers

    International Nuclear Information System (INIS)

    Mickalonis, J.; Dunn, K.

    2009-01-01

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

  5. The effect of initial stress induced during the steel manufacturing process on the welding residual stress in multi-pass butt welding

    Directory of Open Access Journals (Sweden)

    Jeong-ung Park

    2018-03-01

    Full Text Available A residual stress generated in the steel structure is broadly categorized into initial residual stress during manufacturing steel material, welding residual stress caused by welding, and heat treatment residual stress by heat treatment. Initial residual stresses induced during the manufacturing process is combined with welding residual stress or heat treatment residual stress, and remained as a final residual stress. Because such final residual stress affects the safety and strength of the structure, it is of utmost importance to measure or predict the magnitude of residual stress, and to apply this point on the design of the structure. In this study, the initial residual stress of steel structures having thicknesses of 25 mm and 70 mm during manufacturing was measured in order to investigate initial residual stress (hereinafter, referred to as initial stress. In addition, thermal elastic plastic FEM analysis was performed with this initial condition, and the effect of initial stress on the welding residual stress was investigated. Further, the reliability of the FE analysis result, considering the initial stress and welding residual stress for the steel structures having two thicknesses, was validated by comparing it with the measured results. In the vicinity of the weld joint, the initial stress is released and finally controlled by the weld residual stress. On the other hand, the farther away from the weld joint, the greater the influence of the initial stress. The range in which the initial stress affects the weld residual stress was not changed by the initial stress. However, in the region where the initial stress occurs in the compressive stress, the magnitude of the weld residual compressive stress varies with the compression or tension of the initial stress. The effect of initial stress on the maximum compression residual stress was far larger when initial stress was considered in case of a thickness of 25 mm with a value of 180

  6. Residual stress in ion implanted titanium nitride studied by parallel beam glancing incidence x-ray diffraction

    International Nuclear Information System (INIS)

    Geist, D.E.; Perry, A.J.; Treglio, J.R.; Valvoda, V.; Rafaja, D.

    1995-01-01

    Ion implantation is known to increase the lifetime of cutting tools. Current theories are the increase in lifetime is caused by an increase in the residual stress, or by work hardening of the surface associated with the implantation. In this work the effect of ion implantation on the residual stress in titanium nitride coatings made by the standard industrial methods of chemical and physical vapor deposition (CVD and PVD) is studied. It is found in the as-received condition (unimplanted), the residual stress levels are near zero for CVD materials and highly compressive, of the order of 6 GPa, for PVD materials. Ion implantation has no effect on the residual stress in the coatings made by CVD. Nitrogen does increase the compressive residual stress by some 10% in the near surface regions of PVD coatings, while nickel-titanium dual metal ion implantation does not have any effect. It appears that the lifetime increase is not associated with residual stress effects

  7. Residual stresses evaluation in a gas-pipeline crossing

    Energy Technology Data Exchange (ETDEWEB)

    Fonseca, Maria Cindra [Universidade Federal Fluminense (UFF), Niteroi, RJ (Brazil); Almeida, Manoel Messias [COMPAGAS, Curitiba, PR (Brazil); Rebello, Joao Marcos Alcoforado [Universidade Federal do Rio de Janeiro (UFRJ), RJ (Brazil); Souza Filho, Byron Goncalves de [PETROBRAS, Rio de Janeiro, RJ (Brazil)

    2009-07-01

    The X-rays diffraction technique is a well established and effectiveness method in the determination of the residual and applied stresses in fine grained crystalline materials. It allows to characterize and to quantify the magnitude and direction of the existing surface stresses in the studied point of the material. The objective of this work is the evaluation of the surface stresses in a 10 in diameter Natural Gas Distribution Pipeline manufactured from API 5 L Gr B steel of COMPAGAS company, in a crossing with a Natural Gas Transportation Pipeline, in Araucaria-PR. This kind of evaluation is important to establish weather you have to perform a repositioning of one of the pipeline or not. The measurements had been made in two transversal sections of the pipe, the one upstream (170 mm of the external wall of the pipeline) and another one downstream (840 mm of the external wall of the pipeline). Each transversal section measurements where carried out in 3 points: 9 hours, 12 hours and 3 hours. In each measured point of the pipe surface, the longitudinal and transversal stresses had been measured. The magnitude of the surface residual stresses in the pipe varied of +180 MPa at the -210 MPa. The residual stress state on the surface of the points 12 hours region is characterized by tensile stresses and by compressive stresses in the points of 3 and 9 hours region. The surface residual stresses in gas-pipeline have been measured using X-ray diffraction method, by double exposure technique, using a portable apparatus, with Cr-K-alpha radiation. (author)

  8. Residual stress reduction in the penetration nozzle weld joint by overlay welding

    International Nuclear Information System (INIS)

    Jiang, Wenchun; Luo, Yun; Wang, B.Y.; Tu, S.T.; Gong, J.M.

    2014-01-01

    Highlights: • Residual stress reduction in penetration weld nozzle by overlay welding was studied. • The overlay weld can decrease the residual stress in the weld root. • Long overlay welding is proposed in the actual welding. • Overlay weld to decrease residual stress is more suitable for thin nozzle. - Abstract: Stress corrosion cracking (SCC) in the penetration nozzle weld joint endangers the structural reliability of pressure vessels in nuclear and chemical industries. How to decrease the residual stress is very critical to ensure the structure integrity. In this paper, a new method, which uses overlay welding on the inner surface of nozzle, is proposed to decrease the residual stresses in the penetration joint. Finite element simulation is used to study the change of weld residual stresses before and after overlay welding. It reveals that this method can mainly decrease the residual stress in the weld root. Before overlay welding, large tensile residual stresses are generated in the weld root. After overlay weld, the tensile hoop stress in weld root has been decreased about 45%, and the radial stress has been decreased to compressive stress, which is helpful to decrease the susceptibility to SCC. With the increase of overlay welding length, the residual stress in weld root has been greatly decreased, and thus the long overlay welding is proposed in the actual welding. It also finds that this method is more suitable for thin nozzle rather than thick nozzle

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

    Energy Technology Data Exchange (ETDEWEB)

    Nelson, Stacy Michelle [Sandia National Lab. (SNL-CA), Livermore, CA (United States); Hanson, Alexander Anthony [Sandia National Lab. (SNL-CA), Livermore, CA (United States); Briggs, Timothy [Sandia National Lab. (SNL-CA), Livermore, CA (United States); Werner, Brian T. [Sandia National Lab. (SNL-CA), Livermore, CA (United States)

    2017-07-01

    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 and 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

  10. Ultrasonic measurements on residual stress in autofrettged thick walled petroleum pipes

    International Nuclear Information System (INIS)

    Woias, G.; Mizera, J.

    2008-01-01

    The residual stresses in a component or structure are caused by incompatible permanent deformation and related gradient of plastic/elastic strains. They may be generated or modified at every stage in the components life cycle, from original material production to final disposal. Residual stresses can be measured by non-destructive techniques, including X-ray and neutron diffraction, magnetic and ultrasonic methods. The selection of the optimum measurement technique should take account volumetric resolution, material, geometry and access to the component. For large metallic components neutron diffraction is of prime importance as it provides quantitative information on stresses in relatively large volume of methods disregarding its shape complexity. Residual stresses can play a significant role in explaining or preventing failure of components of industrial installations. One example of residual stresses preventing failure are the ones generated by shot peening, inducing surface compressive stresses that improve the fatigue life. Petroleum refinery piping is generally characterized by large-diameters, operated at elevated temperature and under high pressure. Pipelines of a polyethylene plant working in one of the Polish refineries are subjected to pressures exceeding 300 MPa at temperatures above 200 o C. The pipes considered here were pressurized with pressure of 600 MPa. The wall thickness of the pipes is 27 mm and pipe dimensions are 46 x 100 mm. The material is steel with Re=580 MPa. Due to pressurizing, the components retain compressive stresses at the internal surface. These stresses increase resistance to cracking of the pipes. Over the period of exploitation these stresses diminish due to temperature activated relaxation or creep. The purpose of the project is to verify kinetics of such a relaxation process and calibrate alternative methods of their measurements. To avoid stress relaxation, numerical analysis from Finite Element Modelling (FEM)gave an

  11. Residual stresses analysis of friction stir welding using one-way FSI simulation

    International Nuclear Information System (INIS)

    Kang, Sung Wook; Jang, Beom Seon; Song, Ha Cheol

    2015-01-01

    When certain mechanisms, such as plastic deformations and temperature gradients, occur and are released in a structure, stresses remain because of the shape of the structure and external constraints. These stresses are referred to as residual stresses. The base material locally expands during heating in the welding process. When the welding is completed and cooled to room temperature, the residual stresses are left at nearly the yield strength level. In the case of friction stir welding, the maximum temperature is 80% to 90% of the melting point of the materials. Thus, the residual stresses in the welding process are smaller than those in other fusion welding processes; these stresses have not been considered previously. However, friction stir welding residual stresses are sometimes measured at approximately 70% or above. These residual stresses significantly affect fatigue behavior and lifetime. The present study investigates the residual stress distributions in various welding conditions and shapes of friction stir welding. In addition, the asymmetric feature is considered in temperature and residual stress distribution. Heat transfer analysis is conducted using the commercial computational fluid dynamics program Fluent, and results are used in the finite element structural analysis with the ANSYS Multiphysics software. The calculated residual stresses are compared with experimental values using the X-ray diffraction method.

  12. Development of an on-site measurement method for residual stress in primary system piping of nuclear power plants

    International Nuclear Information System (INIS)

    Maekawa, Akira; Takahashi, Shigeru; Fujiwara, Masaharu

    2014-01-01

    In residual stress measurement for large-scale pipes and vessels in high radiation areas and highly contaminated areas of nuclear plants, it is difficult to bring the radioactivated pipes and vessels out of the areas as they are. If they can brought out, it is very burdensome to handle them for the measurement. Development of an on-site measurement method of residual stress which can be quickly applied and has sufficient measurement accuracy is desirable. In this study, a new method combining an electric discharge skim-cut method with a microscopic strain measurement method using markers was proposed to realize the on-site residual stress measurement on pipes in high radiation areas and highly contaminated areas. In the electric discharge skim-cut method, a boat-type sample is skimmed out of a pipe outer/inner surface using electric discharge machining and released residual stress is measured. The on-site measurement of residual stress by the method can be done using a small, portable electric discharge machine. In the microscopic strain measurement method using markers, the residual stress is estimated by microscopic measurement of the distance between markers after the stress release. The combination of both methods can evaluate the residual stress with the same accuracy as conventional methods offer and it can achieve reduction of radiation exposure in the measurement because the work is done simply and rapidly. In this study, the applicability of the electric discharge skim-cut method was investigated because the applicability of the microscopic strain measurement method using markers was confirmed previously. The experimental examination clarified the applicable conditions for the residual stress measurement with the same accuracy as the conventional methods. Furthermore, the electric discharge machining conditions using pure water as the machining liquid was found to eliminate the amount of liquid radioactive waste completely. (author)

  13. Optical residual stress measurement in TFT-LCD panels

    Science.gov (United States)

    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.

  14. Residual Stress Analysis of Aircraft Part using Neutron Beam

    Energy Technology Data Exchange (ETDEWEB)

    Shin, Eun Joo; Seong, Baek Seok; Sim, Cheul Muu [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2012-05-15

    A precise measurement of the residual stress magnitude and distribution is an important factor to evaluate the lifetime or safety of the materials, because the residual stress affects the material properties, such as the strength, fatigue, etc. In the case of a fighter jet, the lifetime and safety of the parts of the landing gear are more important than that of a passenger airplane because of its frequent take offs and landings. In particular in the case of training a fighter jet, a precise evaluation of life time for the parts of the landing gear is strongly required for economic reason. In this study, the residual stress of a part of the landing gear of the training fighter jet which is used to fix the landing gear to the aircraft body was investigated. The part was used for 2000 hours of flight, which corresponds to 10 years. During this period, the fighter jet normally takes off and lands more than 2000 times. These frequent take off and landing can generate residual stress and cause a crack in the part. By measuring the neutron diffraction peaks, we evaluated the residual stress of the landing gear part

  15. The maximum possible stress intensity factor for a crack in an unknown residual stress field

    International Nuclear Information System (INIS)

    Coules, H.E.; Smith, D.J.

    2015-01-01

    Residual and thermal stress fields in engineering components can act on cracks and structural flaws, promoting or inhibiting fracture. However, these stresses are limited in magnitude by the ability of materials to sustain them elastically. As a consequence, the stress intensity factor which can be applied to a given defect by a self-equilibrating stress field is also limited. We propose a simple weight function method for determining the maximum stress intensity factor which can occur for a given crack or defect in a one-dimensional self-equilibrating stress field, i.e. an upper bound for the residual stress contribution to K I . This can be used for analysing structures containing defects and subject to residual stress without any information about the actual stress field which exists in the structure being analysed. A number of examples are given, including long radial cracks and fully-circumferential cracks in thick-walled hollow cylinders containing self-equilibrating stresses. - Highlights: • An upper limit to the contribution of residual stress to stress intensity factor. • The maximum K I for self-equilibrating stresses in several geometries is calculated. • A weight function method can determine this maximum for 1-dimensional stress fields. • Simple MATLAB scripts for calculating maximum K I provided as supplementary material.

  16. Application of x-ray residual stress measurement to products

    International Nuclear Information System (INIS)

    Goto, T.; Iwamura, T.

    1975-01-01

    The X-ray residual stress measuring method is the only nondestructive method for measuring residual stress in polycrystalline materials. It is capable of obtaining information not only on macroscopic stress but also microscopic stress. The authors are employing this method for the development of pre-service and in-service inspection methods and for the improvement of various manufacturing techniques. In this paper, the results of measurement of some products as examples of its application are described. The examples introduced concern the following: (1) Selection of optimum conditions in heat treatment and stress-relief treatment. (2) Residual stress produced by mechanical processes such as autofrettage and flow form. (3) Check of manufacturing processes of rotary shaft and welded parts. (4) Estimation of fatigue strength of shot-peened part. (5) Detection of fatigue damage of shot-peened part. (auth.)

  17. Joining of molybdenum disilicide to stainless steel using amorphous metal brazes - residual stress analysis

    Energy Technology Data Exchange (ETDEWEB)

    Vaidya, R.U.; Gallegos, D.E.; Kautz, D.D. [Los Alamos National Lab. (United States)

    2007-07-01

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

  18. On residual stress prescriptions for fitness for service assessment of pipe girth welds

    International Nuclear Information System (INIS)

    Dong, Pingsha; Song, Shaopin; Zhang, Jinmiao; Kim, Myung H.

    2014-01-01

    This paper aims to provide a detailed assessment of some of the existing residual stress profiles stipulated in widely used fitness-for-service assessment codes and standards, such as BS 7910 Appendix Q and API 579 RP Annex E, by taking advantage of some comprehensive residual stress studies that have recently become available. After presenting a case study on which residual stress measurements are available for validating finite element based residual stress analysis procedure, residual stress profiles stipulated in BS 7910 for pipe girth welds are selected for detailed evaluation by comparing residual stress distribution characteristics shown in parametric finite element results. A shell theory based full-field residual stress profile estimation scheme is then presented to illustrate how an improved estimation of residual stress profiles can be achieved in light of some of the deficiencies in BS 7910 and API 579 identified in this study. - Highlights: • Critically assessed girth weld residual stress profiles in major FFS Codes and Standards. • Identified deficiencies in relating to pipe geometry, heat input, and axial distance from weld. • Presented a shell theory based scheme for prescribing full-field residual stress profiles

  19. Residual stress measurements in thick structural weldments by means of neutron diffraction

    International Nuclear Information System (INIS)

    Ohms, C.; Youtsos, A.G.; Idsert, P. v.d.; Timke, T.

    2000-01-01

    Welding residual stresses in large structural components are a major concern with respect to their performance and lifetime. In large structures reasonable thermal stress relief treatment is usually impossible due to the component size. On the other hand, prediction of welding stresses by numerical modelling has not yet proven to be generally reliable, while the experimental determination of such stresses remains a demanding task. At the high flux reactor (HFR), Petten, a new residual stress diffractometer has been installed recently capable of handling of components up to 1000 kg - the large component neutron diffraction facility (LCNDF). It has facilitated residual stress measurements in two large welded components, of which results are presented here. The first component represents a bi-metallic weld in form of a pipe of 25 mm wall thickness. Three dimensional measurements of residual stress are discussed in detail. The second specimen is a 66 mm wall thickness austenitic steel nuclear piping weld. Results on relief of strain within the weld through post weld heat treatment (PWHT) are presented. Additionally results obtained earlier at former CRNL (CAN) on a section of a thick nuclear piping weld are presented in order to illustrate the variation in the reference lattice parameter trough the weld and the heat affected zone (HAZ). These results clearly show the necessity to determine the reference parameters for each location in all measurement directions by means of measurements in small coupons free of macro-stresses. (orig.)

  20. Residual stresses in a bulk metallic glass-stainless steel composite

    Energy Technology Data Exchange (ETDEWEB)

    Aydiner, C.C. [Department of Materials and Science Engineering, Iowa State University, Ames, IA 50011 (United States); Uestuendag, E. [Department of Materials and Science Engineering, Iowa State University, Ames, IA 50011 (United States)]. E-mail: ustundag@iastate.edu; Clausen, B. [Lujan Neutron Science Center, Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Hanan, J.C. [Division of Engineering and Applied Science, California Institute of Technology, Pasadena, CA 91125 (United States); Winholtz, R.A. [Department of Mechanical and Aerospace Engineering and Research Reactor Center, University of Missouri, Columbia, MO 65211 (United States); Bourke, M.A.M. [Materials Science and Technology Division, Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Peker, A. [Liquidmetal Technologies, Lake Forest, CA 92630 (United States)

    2005-06-15

    Bulk metallic glasses (BMGs) are new structural materials with impressive mechanical properties. They can now be cast into large dimensions, which can lead to significant residual stress generation due to thermal tempering. In this process, a surface compression develops balanced with tension in the interior. To evaluate this phenomenon non-destructively, a model cylindrical stainless steel (SS)-BMG composite was prepared and studied using neutron diffraction and finite element (FE) modeling. The residual strain data from the SS obtained by diffraction were used in modeling calculations to show that significant tempering could be achieved in the composite (about -200 MPa surface compression in the SS). The strong bond between the SS and BMG allowed efficient load transfer and facilitated stress generation. The final values of the residual stresses were seen to be relatively insensitive to the high temperature constitutive behavior of the SS due to the physics of the thermal tempering in BMGs. The approach presented here constitutes an effective means to study non-destructively thermal tempering in BMGs.

  1. Residual stresses in a bulk metallic glass-stainless steel composite

    International Nuclear Information System (INIS)

    Aydiner, C.C.; Uestuendag, E.; Clausen, B.; Hanan, J.C.; Winholtz, R.A.; Bourke, M.A.M.; Peker, A.

    2005-01-01

    Bulk metallic glasses (BMGs) are new structural materials with impressive mechanical properties. They can now be cast into large dimensions, which can lead to significant residual stress generation due to thermal tempering. In this process, a surface compression develops balanced with tension in the interior. To evaluate this phenomenon non-destructively, a model cylindrical stainless steel (SS)-BMG composite was prepared and studied using neutron diffraction and finite element (FE) modeling. The residual strain data from the SS obtained by diffraction were used in modeling calculations to show that significant tempering could be achieved in the composite (about -200 MPa surface compression in the SS). The strong bond between the SS and BMG allowed efficient load transfer and facilitated stress generation. The final values of the residual stresses were seen to be relatively insensitive to the high temperature constitutive behavior of the SS due to the physics of the thermal tempering in BMGs. The approach presented here constitutes an effective means to study non-destructively thermal tempering in BMGs

  2. Effect of residual stresses on fatigue strength of plasma nitrided 4140 steel

    International Nuclear Information System (INIS)

    Aghazadeh, J.; Amidi, M.R.

    2004-01-01

    Almost every method that has been presented to determine residual stress has some limitation and complexities. The aim of this work is to present a new, yet simple method so called strain indentation for measuring the residual stresses particularly in thin layers. In this method in addition to the precision measurements, components of residual stress at different directions may be determined. AISI 4140 steel specimens nitrided at 350 d ig C , 450 d ig C and 550 d ig C for 5 hours in the mixture of 75% nitrogen- 25% hydrogen gas. The, components of residual stress in the radials axial and hoop directions in the nitrided layer were determined considering the elastic strain recovery after removal of residual stress inducer(i.e. the nitrided layer). Fatigue strength of the nitrided specimens was obtained by plotting the S-N curves and fractographic studies carried out on the fracture surface of the specimens. The effect of residual stress on the stress pattern was simulated. The calculated residual stress components were in the range of 40-210 Mpa and the radial components of residual stress were more than the other two directions. Maximum fatigue strength improvement of up to 110% was observed in the plasma nitrided specimens at 550 d ig C and also 40% improvement in fatigue strength was detected by increasing the nitriding temperature from 350 d ig C to 550 d ig C . This was due to 100% increase in residual stress. Fatigue crack growth velocity in the hoop direction was more than that of radial direction. This seems to be due to higher radial residual stress component compared with the hoop stress component in the sub layer

  3. Analysis of residual stress relief mechanisms in post-weld heat treatment

    International Nuclear Information System (INIS)

    Dong, Pingsha; Song, Shaopin; Zhang, Jinmiao

    2014-01-01

    This paper presents a recent study on weld residual stress relief mechanisms associated with furnace-based uniform post-weld heat treatment (PWHT). Both finite element and analytical methods are used to quantitatively examine how plastic deformation and creep relaxation contribute to residual stress relief process at different stages of PWHT process. The key contribution of this work to an improved understanding of furnace based uniform PWHT can be summarized as follows: (1)Plastic deformation induced stress relief during PWHT can be analytically expressed by the change in material elastic deformation capacity (or elastic deformation limit) measured in terms of material yield strength to Young's modulus ratio, which has a rather limited role in overall residual stress relief during furnace based uniform PWHT. (2)The most dominant stress relief mechanism is creep strain induced stress relaxation, as expected. However, a rapid creep strain development accompanied by a rapid residual stress reduction during heating stage before reaching PWHT temperature is shown to contribute to most of the stress relief seen in overall PWHT process, suggesting PWHT hold time can be significantly reduced as far as residual stress relief is concerned. (3)A simple engineering scheme for estimating residual stress reduction is proposed based on this study by relating material type, PWHT temperature, and component wall thickness. - Highlights: • The paper clarified effects of plastic deformation and creep relaxation on weld residual stress relief during uniform PWHT. • Creep strain development is far more important than plastic strain, mostly completed even before hold time starts. • Plastic strain development is insignificant and be analytically described by a material elastic deformation capacity parameter. • An engineering estimation scheme is proposed for determining residual stress reduction resulted from furnace based PWHT

  4. Neutron diffraction measurements of residual stress in a powder metallurgy component

    International Nuclear Information System (INIS)

    Schneider, L.C.R.; Hainsworth, S.V.; Cocks, A.C.F.; Fitzpatrick, M.E.

    2005-01-01

    Residual stresses in a typical industrial green component were determined using neutron diffraction. The measured residual stresses were found to correlate with cross-sectional variations. Residual stress at the edge of the compact in contact with the die wall during compaction reached up to +80 MPa (tension) and -100 MPa (compression)

  5. Analysis of residual stresses in a long hollow cylinder

    International Nuclear Information System (INIS)

    Tokovyy, Yuriy V.; Ma, Chien-Ching

    2011-01-01

    This paper presents an analytical method for solving the axisymmetric stress problem for a long hollow cylinder subjected to locally-distributed residual (incompatible) strains. This method is based on direct integration of the equilibrium and compatibility equations, which thereby have been reduced to the set of two governing equations for two key functions with corresponding boundary and integral conditions. The governing equations were solved by making use of the Fourier integral transformation. Application of the method is illustrated with an analysis of the welding residual stresses in a butt-welded thick-walled pipe. - Highlights: → A solution to the axisymmetric stress problem for a hollow cylinder is constructed. → The cylinder is subjected to a field of locally-distributed residual strains. → The method is based on direct integration of the equilibrium equations. → An application of our solution to analysis of welding residual stresses is considered.

  6. Effects of distance from center of a weld to fixed end on residual stress and stress intensity factor of a piping weld. Evaluation of SCC growth under residual stress field. Report 1

    International Nuclear Information System (INIS)

    Miyazaki, Katsumasa; Numata, Masanori; Saito, Koichi; Mochizuki, Masahito

    2006-01-01

    The fixed conditions of butt welds between straight pipe and valve or pump in the actual piping system are different from those of straight pipes. However, the effect of fixed condition on the residual stress and the stress intensity factor for evaluation of structural integrity of cracked piping was not clear. In this study, the finite element analyses were conducted by considering the differences in the distance from the center of weld to the fixed end L to clarify the effect of fixed condition on the residual stress and the stress intensity factor. For the 600 A piping, the axial residual stress distribution was not affected by the distance L. Furthermore, the stress intensity factor of circumferential crack under the residual stress field with fixed condition could be estimated by using the existing simplified solution for piping. (author)

  7. Effects of residual stress on irradiation hardening in stainless steels

    Energy Technology Data Exchange (ETDEWEB)

    Okubo, N.; Kondo, K.; Kaji, Y. [Japan Atomic Energy Agency, Tokai-mura, Naga-gun, Ibaraki-ken (Japan); Miwa, Y. [Nuclear Energy and Science Directorate, Japan Atomic Energy Agency, Tokai-mura, Ibaraki-ken (Japan)

    2007-07-01

    Full text of publication follows: Structural materials in fusion reactor with water cooling system will undergo corrosion in aqueous environment and heavier irradiation than that in LWR. Irradiation assisted stress corrosion (IASCC) may be induced in stainless steels exposed in these environment for a long term of reactor operation. The IASCC is considered to be caused in a welding zone. It is difficult to predict and estimate the IASCC, because several irradiation effects (irradiation hardening, swelling, irradiation induced stress relaxation, etc) work intricately. Firstly, effects of residual stress on irradiation hardening were investigated in stainless steels. Specimens used in this study were SUS316 and SUS316L. By bending deformation, the specimens with several % plastic strain, which corresponds to weld residual stress, were prepared. Ion irradiations of 12 MeV Ni{sup 3+} were performed at 330, 400 and 550 deg. C to 45 dpa in TIARA facility at JAEA. No bent specimen was simultaneously irradiated with the bent specimen. The residual stress was estimated by X-ray residual stress measurements before and after the irradiation. The micro-hardness was measured by using nano-indenter. The irradiation hardening and the stress relaxation were changed by irradiation under bending deformation. The residual stress did not relax even for the case of the higher temperature aging at 500 deg. C for the same time of irradiation. The residual stress after ion irradiation, however, relaxed at these experimental temperatures in SUS316L. The hardness was obviously suppressed in bent SUS316L irradiated at 300 deg. C to 6 or 12 dpa. It was evident that irradiation induced stress relaxation occasionally suppressed the irradiation hardening in SUS316L. (authors)

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

    Science.gov (United States)

    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.

  9. Investigation of Performance and Residual Stress Generation of AlSi10Mg Processed by Selective Laser Melting

    Directory of Open Access Journals (Sweden)

    Lianfeng Wang

    2018-01-01

    Full Text Available During the selective laser melting (SLM process, the scanned layers are subjected to rapid thermal cycles. By working on the mechanical properties, residual stress, and microstructure, the high-temperature gradients can have significant effect on the proper functioning and the structural integrity of built parts. This work presents a comprehensive study on the scanning path type and preheating temperature for AlSi10Mg alloy during SLM. According to the results, SLM AlSi10Mg parts fabricated in chessboard scanning strategy have higher mechanical properties or at least comparable to the parts fabricated in uniformity scanning strategy. In the SLM processing, the residual stress in different parts of the specimen varies with temperature gradient, and the residual stress at the edge of the specimen is obviously larger than that at the center. Under the chessboard scanning and preheating temperature 160°C, the residual stress in each direction of the specimens reaches the minimum. Under different forming processes, the morphology of the microstructure is obviously different. With the increase of preheating temperature, the molten pool in the side surface is obviously elongated and highly unevenly distributed. From the coupling relationship between the residual stress and microstructure, it can be found that the microstructure of top surface is affected by residual stresses σx and σy. But the side surface is mainly governed by residual stress σy; moreover, the greater the residual stress, the more obvious the grain tilt. In the XY and XZ surfaces, the scanning strategy has little influence on the tilt angle of the grain. But, the tilt angle and morphology of the microstructure are obviously affected by the preheating temperature. The results show that the residual stresses can effectively change the properties of the materials under the combined influence of scanning strategy and preheating temperature.

  10. Optimum injection pressure of a cavitating jet on introduction of compressive residual stress into stainless steel

    International Nuclear Information System (INIS)

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

    2011-01-01

    In order to mitigate stress corrosion cracking of components used for nuclear power plants, introduction of compressive residual stress into sub-surface of the components is an effective maintenance method. The introduction of compressive residual stress using cavitation impact generated by injecting a high speed water jet into water was proposed. Water jet peening is now applying to reduce stress corrosion cracking of shrouds in the nuclear power plants. However, accidental troubles such as dropping off the components and cutting of the pipes by the jet occurred at the maintenance. In order to peen by the jet without damage, optimum injection pressure of the jet should be revealed. In the case of 'cavitation peening', cavitation is generated by injecting the high speed water jet into water. As working pressure at the cavitation peening is the pressure at cavitation bubble collapse, the injection pressure of the jet is not main parameter. The cavitation impact is increasing with the scale of the jet, i.e., scaling effect of the cavitation. It was revealed that the large scale jet at low injection pressure can introduce compressive residual stress into stainless steel comparing with the small scale jet at high injection pressure. As expected, a water jet at high injection pressure might make damage of the components. Namely, in order to avoid damage of the components, the jet at the low injection pressure will be suit for the introduction of compressive residual stress. In the present paper, in order to make clear optimum injection pressure of the cavitating jet for the introduction of compressive residual stress without damage, the residual stress of stainless steel treated by the jet at various injection pressure was measured by using an X-ray diffraction method. The injection pressure of the jet p 1 was varied from 5 MPa to 300 MPa. The diameter of the nozzle throat of the jet d was varied from 0.35 mm to 2.0 mm. The residual stress changing with depth was

  11. Effect of residual stress on the nanoindentation response of (100) copper single crystal

    International Nuclear Information System (INIS)

    Zhu, Li-na; Xu, Bin-shi; Wang, Hai-dou; Wang, Cheng-biao

    2012-01-01

    Experimental measurements were used to investigate the effect of residual stress on the nanoindentation of (100) copper single crystal. Equi-biaxial tensile and compressive stresses were applied to the copper single crystal using a special designed apparatus. It was found that residual stresses greatly affected peak load, curvature of the loading curve, elastically recovered depth, residual depth, indentation work, pile-up amount and contact area. The Suresh and Giannakopoulos and Lee and Kwon methods were used to calculate the residual stresses from load-depth data and morphology observation of nanoindents using atomic force microscopy. Comparison of the obtained results with stress values from strain gage showed that the residual stresses analyzed from the Suresh and Giannakopoulos model agreed well with the applied stresses. -- Highlights: ► Residual stresses greatly affected various nanoindentation parameters. ► The contact area can be accurately measured from AFM observation. ► The residual stresses analyzed from the S and G model agreed well with applied stresses.

  12. Convenient measurement of the residual stress using X-ray penetration depth

    International Nuclear Information System (INIS)

    Ukai, Takayoshi; Shibano, Junichi

    1994-01-01

    The residual stress measured with a characteristic X-ray is usually evaluated as a surface stress. However, it is a weighted mean value over all penetration depth of X-ray. Thus, the classical sin 2 Ψ method with the characteristic X-ray is difficult to use for measuring the steep gradient of residual stress that occurs along the depth direction in a subsurface layer of the material after cold rolling and grinding. This paper presents a convenient method of the residual stress measurement along the depth direction in a subsurface layer using the penetration depth depending on a characteristic X-ray. The residual stress distribution of JIS SKS51 steel plate was measured as an example of applying this method. As a result, it could be confirmed that a residual stress distribution along the depth direction in a subsurface layer could be evaluated nondestructively by this convenient method. (author)

  13. Residual stresses and fatigue in a duplex stainless steel

    International Nuclear Information System (INIS)

    Johansson, Johan

    1999-01-01

    Duplex stainless steels, consisting of approximately equal amounts of austenite and ferrite, often combine the best features of austenitic and ferritic stainless steels. They generally have good mechanical properties, including high strength and ductility, and the corrosion resistance is often better than conventional austenitic grades. This has lead to a growing use of duplex stainless steels as a material in mechanically loaded constructions. However, detailed knowledge regarding its mechanical properties and deformation mechanisms are still lacking. In this thesis special emphasis has been placed on the residual stresses and their influence on mechanical behaviour of duplex stainless steels. Due to the difference in coefficient of thermal expansion between the two phases, tensile microstresses are found in the austenitic phase and balancing compressive microstresses in the ferritic phase. The first part of this thesis is a literature survey, which will give an introduction to duplex stainless steels and review the fatigue properties of duplex stainless steels and the influence of residual stresses in two-phase material. The second part concerns the evolution of the residual stress state during uniaxial loading. Initial residual stresses were found to be almost two times higher in the transverse direction compared to the rolling direction. During loading the absolute value of the microstresses increased in the macroscopic elastic regime but started to decrease with increasing load in the macroscopic plastic regime. A significant increase of the microstresses was also found to occur during unloading. Finite element simulations also show stress variation within one phase and a strong influence of both the elastic and plastic anisotropy of the individual phases on the simulated stress state. In the third part, the load sharing between the phases during cyclic loading is studied. X-ray diffraction stress analysis and transmission electron microscopy show that even if

  14. Residual stresses and fatigue in a duplex stainless steel

    Energy Technology Data Exchange (ETDEWEB)

    Johansson, Johan

    1999-05-01

    Duplex stainless steels, consisting of approximately equal amounts of austenite and ferrite, often combine the best features of austenitic and ferritic stainless steels. They generally have good mechanical properties, including high strength and ductility, and the corrosion resistance is often better than conventional austenitic grades. This has lead to a growing use of duplex stainless steels as a material in mechanically loaded constructions. However, detailed knowledge regarding its mechanical properties and deformation mechanisms are still lacking. In this thesis special emphasis has been placed on the residual stresses and their influence on mechanical behaviour of duplex stainless steels. Due to the difference in coefficient of thermal expansion between the two phases, tensile microstresses are found in the austenitic phase and balancing compressive microstresses in the ferritic phase. The first part of this thesis is a literature survey, which will give an introduction to duplex stainless steels and review the fatigue properties of duplex stainless steels and the influence of residual stresses in two-phase material. The second part concerns the evolution of the residual stress state during uniaxial loading. Initial residual stresses were found to be almost two times higher in the transverse direction compared to the rolling direction. During loading the absolute value of the microstresses increased in the macroscopic elastic regime but started to decrease with increasing load in the macroscopic plastic regime. A significant increase of the microstresses was also found to occur during unloading. Finite element simulations also show stress variation within one phase and a strong influence of both the elastic and plastic anisotropy of the individual phases on the simulated stress state. In the third part, the load sharing between the phases during cyclic loading is studied. X-ray diffraction stress analysis and transmission electron microscopy show that even if

  15. Residual stress in the first wall coating materials of TiC and TiN for fusion reactor

    International Nuclear Information System (INIS)

    Qiu Shaoyu

    1997-01-01

    Residual stresses measurement in the first wall coating of a fusion reactor of TiC and TiN films by X-ray diffraction 'sin 2 ψ methods' were described. The authors have studied on the effect of conditions of specimen preparation (such as coating method, substrate materials, film thickness and deposition temperature) on the residual stress of TiC and TiN films coated onto Mo, 316LSS and Pocographite by chemical vapor deposition (CVD) and physical vapor deposition (PVD) method. All films prepared in this study were found to have a compressive stresses and the CVD method gave lower residual stress than PVD method. TiC film coated on Mo substrate at 1100 degree C by CVD method showed that residual stress as the film thickness was raised from 14 μm to 60 μm, on the other hand, residual stress by PVD method exhibited a high compressive stresses, this kind of stress was principally the intrinsic stress, and a marked decrease in the residual with raising the deposition temperature (200 degree C∼650 degree C) was demonstrated. Origins of the residual stress were discussed by correlation with differences between thermal expansion coefficients, and also with fabrication methods

  16. Residual stress in deuterium implanted nominal copper coatings

    International Nuclear Information System (INIS)

    Inal, M. Y.; Alam, M.; Peascoe, R. A.; Watkins, T. R.

    2000-01-01

    The effects of deuterium (D) implantation on the residual stresses in Cu and CuAl 2 phases present in nominal Cu coatings (containing Al) deposited on Al-alloy (Al-6061) substrates were measured using an x-ray diffraction technique. The coatings were deposited by radio frequency magnetron sputtering of a pure Cu target under identical conditions and Al was incorporated in the coatings during growth by diffusion from the substrate. Deuterium was implanted in the coatings at energies of 40 or 40+120 keV with fluences of 1x10 21 , 2x10 21 , or 3x10 21 D + /m 2 . Pole figures of the Cu phase in the coatings prior to and after implantation indicated no effect of implantation on the fibrous texture. Triaxial stress analysis indicated the surface normal stress component to be negligible in Cu and slightly tensile in CuAl 2 under all conditions. Furthermore, under all conditions, the in-plane residual stresses in both phases were found to be compressive and nearly isotropic. The magnitude of the isotropic compressive stress was always higher in CuAl 2 as compared to Cu. The compressive residual stresses in the Cu phase changed only mildly with increasing coating weight, ion energy, and fluence. However, in the CuAl 2 phase the compressive residual stresses changed markedly with increasing ion energy (initial decrease followed by leveling off) and increasing ion fluence (initial decrease followed by an increase), but remained unaffected by increasing coating weight. (c) 2000 American Institute of Physics

  17. finite element model for predicting residual stresses in shielded

    African Journals Online (AJOL)

    eobe

    This paper investigates the prediction of residual stresses developed ... steel plates through Finite Element Model simulation and experiments. ... The experimental values as measured by the X-Ray diffractometer were of ... Based on this, it can be concluded that Finite Element .... Comparison of Residual Stresses from X.

  18. The measurement of residual stresses in claddings

    International Nuclear Information System (INIS)

    Hofer, G.; Bender, N.

    1978-01-01

    The ring core method, a variation of the hole drilling method for the measurement of biaxial residual stresses, has been extended to measure stresses from depths of about 5 to 25mm. It is now possible to measure the stress profiles of clad material. Examples of measured stress profiles are shown and compared with those obtained with a sectioning technique. (author)

  19. Neutron diffraction measurements of residual stresses in NPP construction materials

    International Nuclear Information System (INIS)

    Hinca, R.; Bokuchava, G.

    2001-01-01

    Neutron diffraction is one of the most powerful methods for condensed matter studies. This method is used for non-destructive determination of residual stresses in material. The fundamental aspects of neutron diffraction are discussed, together with a brief description of the experimental facility. The principal advantage of using neutrons rather than the more conventional X-rays is the fact that neutron can penetrate deeply (2-4 cm for steel and more than 10 cm for aluminium) into metals to determine internal parameters within the bulk of materials. We present results of measurements residual stresses in NPP construction material - austenitic stainless steel (Cr-18%, Ni-10%, Ti-1%) coated with high-nickel alloy. (authors)

  20. Laser quench hardening of steel: Effects of superimposed elastic pre-stress on the hardness and residual stress distribution

    Science.gov (United States)

    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.

  1. Determination of global and local residual stresses in SOFC by X-ray diffraction

    International Nuclear Information System (INIS)

    Villanova, Julie; Sicardy, Olivier; Fortunier, Roland; Micha, Jean-Sebastien; Bleuet, Pierre

    2010-01-01

    Solid Oxide Fuel Cell (SOFC) is a high-performance electrochemical device for energy conversion. A single cell is composed of five layers made of different ceramic materials: anode support, anode functional layer, electrolyte, cathode functional layer and cathode. The mechanical integrity of the cell is a major issue during its lifetime, especially for the electrolyte layer. Damage of the cells is mainly due to the high operating temperature, the 'redox' behaviour of the anode and the brittleness of the involved materials. Since residual stresses are known to play a significant role in the damage evolution, it is important to determine them. For this purpose, residual stresses in an anode-supported planar SOFC were measured by X-ray diffraction. Firstly, macroscopic stresses in each phase of each layer were studied using the sin 2 ψ method on a laboratory X-ray goniometer at room temperature. This technique enables the calculation of residual stress of the material from the measurement of the crystal lattice deformation. The electrolyte has been found under bi-axial compressive stress of -920 MPa. Secondly, X-ray measurements controlling depth penetration were made in the electrolyte using grazing incidence method. The results show that the stress is not homogenous in the layer. The first five micrometers of the electrolyte have been found less constrained (-750 MPa) than the complete layer, suggesting a gradient of deformation in the electrolyte from the interface with the Anode Functional Layer to the free surface. Finally, local stress measurements were made on the electrolyte layer by X-ray synchrotron radiation that allows high accuracy measurement on the (sub-) micrometer scale. Polychromatic and monochromatic beams are used to determine the complete strain tensor from grain to grain in the electrolyte. First results confirm the macroscopic stress trend of the electrolyte. These X-ray techniques at different scales will contribute to a better understanding

  2. X-ray residual stress analysis on machined and tempered HPSN-ceramics

    Energy Technology Data Exchange (ETDEWEB)

    Immelmann, S.; Welle, E.; Reimers, W. [Hahn-Meitner-Institut Berlin GmbH (Germany)

    1997-11-15

    The residual stress state induced by grinding and tempering of hot pressed silicon nitride (HPSN) samples is studied by X-ray diffraction. The results reveal that the residual stress values at the surface of the samples as well as their gradient within the penetration depth of the X-rays depend on the sintering aid and thus, on the glassy phase content of the HPSN. Tempering of the ground HPSN reduces the residual stress values due to microplastic deformation, whereas an oxidation of the glassy phase leads to the formation of compressive residual stresses. (orig.) 35 refs.

  3. The influence of texture on residual stress measurements

    International Nuclear Information System (INIS)

    Lima, N.B. de.

    1991-01-01

    A computer program to calculate the orientation distribution function (ODF) from incomplete pole figures has been developed for rolled materials with a cubic structure. This program is based on Bunge's series expansion. The use of incomplete pole figures results in the loss of orthogonality among symmetric spherical harmonic functions and makes it necessary to explicitly evaluate the integrals. The ODF has been used to quantitatively evaluate the influence of texture in determining residual stresses. This has been done by calculating theoretically the strain undergone by each cell as a function of its orientation to residual stress relationship. To test the ODF program, cold rolled Cu and Al specimens were used and to evaluate residual stresses as a function of texture, cold rolled AISI 430 and 324 specimens were used. Simulations have also be presented based on the texture for each of the materials, to verify the nature of the curve d x sin 2 ψ as a function of each stress tensor components. (author)

  4. Determination of residual stresses in roll compacted titanium strips

    CSIR Research Space (South Africa)

    Mothosi, KL

    2017-01-01

    Full Text Available residual stresses using x-ray diffraction (XRD) surface probing technique. Preliminary results were obtained for the surface residual stress at the center of the titanium strips for the 100 and 325 mesh strips rolled at 0.1 roll gap for 20 and 50 mm set...

  5. Simulation of Residual Stresses at Holes in Tempered Glass

    DEFF Research Database (Denmark)

    Nielsen, Jens Henrik; Olesen, John Forbes; Poulsen, Peter Noe

    2010-01-01

    This work presents a full 3D numerical study of the residual stresses in tempered (toughened) glass near holes using Narayanaswamy’s model for the tempering process. It is the objective of the paper to elucidate the influence on the minimal residual compressive stresses at holes from variations in...

  6. Residual stresses in U-bending deformations and expansion joints of heat exchanger tubes

    International Nuclear Information System (INIS)

    Kim, Woo Gon; Kim, Sun Jae; Jang, Jin Sung; Kuk, Ii Hiun; Bae, Kang Gug; Kim, Sung Chung

    2000-01-01

    Residual stress induced in U-bending and tube-to-tubesheet joint processes of PWR's rew-1 heat exchanger tube was measured by X-ray method and Hole-Drilling Method(HDM). Compressive residual stresses(-) at the extrados surface were induced in U-bending, and its maximum value reached -319MPa in axial direction at the position of ψ=0 deg. Tensile residual stresses (+) of 0σ zz =45 MPa and σ θθ =25MPa were introduced in the intrados surface at the position of ψ=0 deg. Maximum tensile residual stress of 170 MPa was measured at the flank side at the position of ψ=90 deg, i.e., at apex region. It was observed that higher stress gradient was generated at the irregular transition regions (ITR). The trend of residual stress induced by U-bending process of the tubes was found to be related with the change of ovality. The residual stress induced by the explosive joint method was found to be lower than that by the mechanical roll method. The gradient of residual stress along the expanded tube was highest at the transition region (TR), and the residual stress in circumferential direction was found to be higher than the residual stress in axial direction

  7. A Study on Residual Stress Measurements by Using Laser Speckle Interferometry

    International Nuclear Information System (INIS)

    Rho, Kyung Wan; Kang, Young June; Hong, Seong Jin; Kang, Hyung Soo

    1999-01-01

    Residual stress is one of the causes which make defects in engineering components and materials. And interest in the measurement of residual stress exists in many industries. There are commonly used methods by which residual stresses are currently measured. But these methods have a little demerits: time consumption and other problems. Therefore we devised a new experimental technique to measure residual stress in materials with a combination of laser speckle pattern interferometry, finite element method and spot heating. The speckle pattern interferometer measures in-plane deformations while the heating provides for very localized stress relief. FEM is used for determining heat temperature and other parameters. The residual stresses are determined by the amount of strain that is measured subsequent to the heating and cool-down of the region being interrogated. A simple model is presented to provide a description of the method. In this paper, the ambiguity problem for the fringe patterns has solved by a phase shifting method

  8. Benchmark on residual stress modeling in fracture mechanics assessment

    International Nuclear Information System (INIS)

    Marie, S.; Deschanels, H.; Chapuliot, S.; Le Delliou, P.

    2014-01-01

    In the frame of development in analytical defect assessment methods for the RSE-M and RCC-MRx codes, new work on the consideration of residual stresses is initiated by AREVA, CEA and EDF. The first step of this work is the realization of a database of F.E. reference cases. To validate assumptions and develop a good practice guideline for the consideration of residual stresses in finite element calculations, a benchmark between AREVA, CEA and EDF is going-on. A first application presented in this paper focuses on the analysis of the crack initiation of aged duplex stainless steel pipes submitted to an increasing pressure loading. Residual stresses are related to pipe fabrication process and act as shell bending condition. Two tests were performed: the first with an internal longitudinal semi-elliptical crack and the second with an external crack. The analysis first focuses on the ability to accurately estimate the measured pressure at the crack initiation of the two tests. For that purpose, the comparison of results obtained with different methods of taking into account the residual stresses (i.e. thermal fields or initial strain field). It then validates post-treatment procedures for J or G determination, and finally compares of the results obtained by the different partners. It is then shown that the numerical models can integrate properly the impact of residual stresses on the crack initiation pressure. Then, an excellent agreement is obtained between the different numerical evaluations of G provided by the participants to the benchmark so that best practice and reference F.E. solutions for residual stresses consideration can be provided based on that work. (authors)

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

    Science.gov (United States)

    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.

  10. Residual stress in ceramics and ceramic composites

    International Nuclear Information System (INIS)

    Oden, M.

    1992-01-01

    Residual stresses in Si 3 N 4 and SiC have been measured with X-ray diffraction after grinding and thermal shock. The produced surface stresses are compressive after both treatments. The stresses show a strong dependence on the quenching temperature up to a certain temperature when cracks relax the stresses. The influence of the amount of reinforcing phase on the residual stress state in a Al 2 O 3 /SiC whisker composite was investigated and correlated to a modified Eshelby model. The agreement is excellent. The composite was quenched in liquid He (4K) and the stress state measured after show no relaxation of stresses, indicating elastic behaviour. An in situ strain measurement as a function of temperature conducted on a Al 2 O 3 /SiC whisker composite and a SiC/TiB 2 particle composite show very good agreement with the Eshelby model for the Al 2 O 3 /SiC system but not agreement for the SiC/TiB 2 system. The reason is believed to be stress relaxation during sample preparation. (au) (53 refs., 24 figs., 14 tabs.)

  11. Residual Stress Studies Using the Cairo Fourier Diffractometer Facility

    International Nuclear Information System (INIS)

    Maayouf, R.M.A.; El-Shaer, Y.H.

    2002-01-01

    The present paper deals with residual stress studies using the Cairo Fourier diffractometer facility CFDF. The CFDF is a reverse - time of -flight (RTOF) diffractometer; applies a Fourier chopper. The measurements were performed for copper samples in order to study the residual stress after welding. The maximum modulation of the Fourier chopper during the measurements was 136 khz; leading to a time resolution half-width of about 7 μ s. It has been found from the present measurements that, the resulting diffraction spectra could be successfully used for studying the residual stress; in the wavelength range between 0.7-2.9 A degree at ∼ 0.45 % relative resolution

  12. Residual stresses under quasi-static and cyclic loading in shot peened Inconel 718

    Energy Technology Data Exchange (ETDEWEB)

    Hoffmeister, Juergen; Schulze, Volker [Karlsruhe Institute of Technology (KIT), Karlsruhe (Germany). Inst. for Applied Materials; Hessert, Roland; Koenig, Gerhard [MTU Aero Engines, Munich (Germany)

    2012-01-15

    The residual stress state induced by shot peening should be taken into account in the dimensioning of turbine components. Understanding the changes in the residual stress state caused by the application of quasi-static and cyclic loads is a prerequisite. In order to describe the residual stress state after quasi-static loading, several different shot peened Inconel 718 specimens were loaded isothermally up to specific tensile loadings. To analyze the residual stress state after cyclic loading, isothermal low cycle fatigue tests were performed. These tests were stopped after a defined number of cycles. Finally, after the specimens had been subjected to different loads, the surface residual stresses and - for special loadings - the residual stress depth distributions were determined experimentally by using X-ray diffraction. The surface - core model was adapted so that the complete residual stress depth distribution after quasi-static and cyclic loading can now be described. (orig.)

  13. Effects of shot peening on the residual stress of welded SS400 steel

    International Nuclear Information System (INIS)

    Lee, Jong Man; Kim, Tae Hyung; Cheong, Seong Kyun; Lee, Seung Ho

    2002-01-01

    The fatigue life of structures is usually determined by welding zone. The tensile residual stress, which is induced by welding, reduces the fatigue life and fatigue strength of welded structures. If we remove the tensile residual stress or induce the compressive residual stress, the fatigue life of welded structures will be improved. The change of hardness and compressive residual stress of welded zone after shot peening was investigated in this paper. The results show that the hardness was increased by shot peening. The residual stress was reduced by shot peening

  14. Temperature dependence of residual stress in TiC coated Mo

    International Nuclear Information System (INIS)

    Yoshizawa, I.; Fukutomi, M.; Kamada, K.

    1984-01-01

    The effects of fabrication temperature and heat treatment on the residual stress in TiC coated Mo have been studied by using X-ray diffractometry. TiC coatings on Mo single crystal substrates with (100) and (111) surfaces were carried out with the Activated Reactive Evaporation (ARE) method. It was found that all Mo substrates measured show tensile residual stresses, and their values decrease as the fabrication temperature increases from 300 to 700 0 C. On the other hand, TiC films measured showed compressive residual stresses, for both TiC/Mo(100) and TiC/Mo(111) specimens. These compressive stresses also decreased with increasing the fabrication temperature. The residual stresses measured were higher in TiC/Mo(100) than in TiC/Mo(111). It was found that the compressive stresses in as-grown TiC films change to the tensile stresses after annealing at 1700 0 C for 30 min. The preferred orientations of TiC films were observed to depend on the fabrication temperature. However, no epitaxial growth of TiC films was found as far as the present experiment was concerned. (orig.)

  15. Residual stresses determination in an 8 mm Incoloy 800H weld via neutron diffraction

    International Nuclear Information System (INIS)

    Chen, Xizhang; Zhang, Shu Yan; Wang, Jingjun; Kelleher, Joe F.

    2015-01-01

    Highlights: • Stress through thickness at 5 mm from weld centerline indicates a “U” distribution. • Declining of tensile stress through thickness occurred at weld centerline. • Residual stress between layers is the lowest. - Abstract: To investigate the distribution of residual stresses, the 8 mm 800H alloy was joined by multi-layer butt TIG process. Residual stresses in the longitudinal, transverse and normal directions were measured via neutron diffraction. These residual stress measurements were taken at a series of points 2 mm below the top surface, covering the fusion zone, heat affected zone (HAZ) and base metal. In addition, two lines of longitudinal residual stress values at the weld centerline and 5 mm from weld centerline through thickness were measured. Results show that both the longitudinal and transverse stresses from the weld centerline to base metal are mainly tensile stresses. The longitudinal residual stress is the largest, with a maximum value of 330 MPa. As for the normal residual stress, the weld zone shows tensile stress, while the HAZ shows compressive stress. The middle of the thickness shows compressive residual stress along the thickness direction. The longitudinal stress at weld centerline through thickness reveals the interlayer heat treat effects leads to a declining of tensile stress. While the stress at 5 mm from weld centerline indicates a “U” distribution due to the mixed microstructure close to fusion line. With the increasing distance from weld seam, the residual stress decreases gradually

  16. Effects on Machining on Surface Residual Stress of SA 508 and Austenitic Stainless Steel

    International Nuclear Information System (INIS)

    Lee, Kyoung Soo; Lee, Seong Ho; Park, Chi Yong; Yang, Jun Seok; Lee, Jeong Geun; Park, Jai Hak

    2011-01-01

    Primary water stress corrosion cracking has occurred in dissimilar weld areas in nuclear power plants. Residual stress is a driving force in the crack. Residual stress may be generated by weld or surface machining. Residual stress due to surface machining depends on the machining method, e.g., milling, grinding, or EDM. The stress is usually distributed on or near the surface of the material. We present the measured residual stress for machining on SA 508 and austenitic stainless steels such as TP304 and F316. The residual stress can be tensile or compressive depending on the machining method. The depth and the magnitude of the residual stress depend on the material and the machining method

  17. Structural transformations in Mn2NiGa due to residual stress

    International Nuclear Information System (INIS)

    Singh, Sanjay; Maniraj, M.; D'Souza, S. W.; Barman, S. R.; Ranjan, R.

    2010-01-01

    Powder x-ray diffraction study of Mn 2 NiGa ferromagnetic shape memory alloy shows the existence of a 7M monoclinic modulated structure at room temperature (RT). The structure of Mn 2 NiGa is found to be highly dependent on residual stress. For higher stress, the structure is tetragonal at RT, and for intermediate stress it is 7M monoclinic. However, only when the stress is considerably relaxed, the structure is cubic, as is expected at RT since the martensitic transition temperature is 230 K.

  18. Experimental evaluation of residual stresses produced by plain dents in pipelines

    Energy Technology Data Exchange (ETDEWEB)

    Pascotto, Jorge [PETROBRAS Transporte S.A. (TRANSPETRO), Rio de Janeiro, RJ (Brazil); Marques, Altino; Fonseca, Maria Cindra [Universidade Federal Fluminense (UFF), Niteroi, RJ (Brazil)

    2009-07-01

    A dent means a permanent plastic deformation of the circular cross-section of the pipe. Dents are potentially danger for structural integrity of onshore and offshore pipelines, because it causes a local stress and strain concentration. It is also expected that residual stresses are introduced by the non-uniform plastic deformation. A plain dent is a dent which causes a smooth change in the curvature of the pipe wall that contains no wall thickness reductions (such as a gouge or a crack) or other defects or imperfections (such as a weld). This work presents an experimental evaluation of residual stresses intensification due to plain dents introduced through the same indentation process, in samples made of the same steel line pipe, commonly used in the pipeline industry. The residual stresses were measured in the longitudinal and circumferential directions in preselected points by X-ray diffraction technique, before indentation. After the samples have been dented, the residual stresses were measured once more at the same points, for comparison. All samples presented a similar behavior of the residual stresses due to induced plain dents, and the X-ray diffraction technique shows itself as an efficient methodology of stress measurement in pipelines. (author)

  19. Effect of residual stress induced by cold expansion on fatigue crack ...

    African Journals Online (AJOL)

    Fatigue life and fatigue crack growth rate are controlled by stress ratio, stress level, orientation of crack, temper-ature, residual stress, corrosion, etc. The effects of residual stress on fatigue crack growth in aluminium (Al) alloy 2024-T351 by Mode I crack were investigated by applying constant amplitude cycles based on ...

  20. Diffraction measurements of residual stress in titanium matrix composites

    International Nuclear Information System (INIS)

    James, M.R.; Bourke, M.A.; Goldstone, J.A.; Lawson, A.C.

    1993-01-01

    Metal matrix composites develop residual strains after consolidation due to the thermal expansion mismatch between the reinforcement fiber and the matrix. X-ray and neutron diffraction measured values for the longitudinal residual stress in the matrix of four titanium MMCs are reported. For thick composites (> 6 plies) the surface stress measured by x-ray diffraction matches that determined by neutron diffraction and therefore represents the stress in the bulk region consisting of the fibers and matrix. For thin sheet composites, the surface values are lower than in the interior and increase as the outer rows of fibers are approached. While a rationale for the behavior in the thin sheet has yet to be developed, accounting for composite thickness is important when using x-ray measured values to validate analytic and finite element calculations of the residual stress state

  1. The effects of machine parameters on residual stress determined using micro-Raman spectroscopy

    Energy Technology Data Exchange (ETDEWEB)

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

    1988-12-01

    The effects of machine parameters on residual stresses in single point diamond turned silicon and germanium have been investigated using micro-Raman spectroscopy. Residual stresses were sampled across ductile feed cuts in < 100 > silicon and germanium which were single point diamond turned using a variety of feed rates, rake angles and clearance angles. High spatial resolution micro-Raman spectra (1{mu}m spot) were obtained in regions of ductile cutting where no visible surface damage was present. The use of both 514-5nm and 488.0nm excitation wavelengths, by virtue of their differing characteristic penetration depths in the materials, allowed determinations of stress profiles as a function of depth into the sample. Previous discussions have demonstrated that such Raman spectra will exhibit asymmetrically broadened peaks which are characteristic of the superposition of a continuum of Raman scatterers from the various depths probed. Depth profiles of residual stress were obtained using computer deconvolution of the resulting asymmetrically broadened raman spectra.

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

    Energy Technology Data Exchange (ETDEWEB)

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

    2016-06-01

    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 encapsulant 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.

  3. Impacts of weld residual stresses and fatigue crack growth threshold on crack arrest under high-cycle thermal fluctuations

    Energy Technology Data Exchange (ETDEWEB)

    Taheri, Said, E-mail: Said.taheri@edf.fr [EDF-LAB, IMSIA, 7 Boulevard Gaspard Monge, 91120 Palaiseau Cedex (France); Julan, Emricka [EDF-LAB, AMA, 7 Boulevard Gaspard Monge, 91120 Palaiseau Cedex (France); Tran, Xuan-Van [EDF Energy R& D UK Centre/School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester M13 9PL (United Kingdom); Robert, Nicolas [EDF-DPN, UNIE, Strategic Center, Saint Denis (France)

    2017-01-15

    Highlights: • For crack growth analysis, weld residual stress field must be considered through its SIF in presence of a crack. • Presence of cracks of same depth proves their arrest, where equal depth is because mean stress acts only on crack opening. • Not considering amplitudes under a fatigue crack growth threshold (FCGT) does not compensate the lack of FGCT in Paris law. • Propagation rates are close for axisymmetric and circumferential semi-elliptical cracks. - Abstract: High cycle thermal crazing has been observed in some residual heat removal (RHR) systems made of 304 stainless steel in PWR nuclear plants. This paper deals with two types of analyses including logical argumentation and simulation. Crack arrest in networks is demonstrated due to the presence of two cracks of the same depth in the network. This identical depth may be proved assuming that mean stress acts only on crack opening and that cracks are fully open during the load cycle before arrest. Weld residual stresses (WRS) are obtained by an axisymmetric simulation of welding on a tube with a chamfer. Axisymmetric and 3D parametric studies of crack growth on: representative sequences for variable amplitude thermal loading, fatigue crack growth threshold (FCGT), permanent mean stress, cyclic counting methods and WRS, are performed with Code-Aster software using XFEM methodology. The following results are obtained on crack depth versus time: the effect of WRS on crack growth cannot be determined by the initial WRS field in absence of crack, but by the associated stress intensity factor. Moreover the relation between crack arrest depth and WRS is analyzed. In the absence of FCGT Paris’s law may give a significant over-estimation of crack depth even if amplitudes of loading smaller than FCGT have not been considered. Appropriate depth versus time may be obtained using different values of FCGT, but axisymmetric simulations do not really show a possibility of arrest for shallow cracks in

  4. Impacts of weld residual stresses and fatigue crack growth threshold on crack arrest under high-cycle thermal fluctuations

    International Nuclear Information System (INIS)

    Taheri, Said; Julan, Emricka; Tran, Xuan-Van; Robert, Nicolas

    2017-01-01

    Highlights: • For crack growth analysis, weld residual stress field must be considered through its SIF in presence of a crack. • Presence of cracks of same depth proves their arrest, where equal depth is because mean stress acts only on crack opening. • Not considering amplitudes under a fatigue crack growth threshold (FCGT) does not compensate the lack of FGCT in Paris law. • Propagation rates are close for axisymmetric and circumferential semi-elliptical cracks. - Abstract: High cycle thermal crazing has been observed in some residual heat removal (RHR) systems made of 304 stainless steel in PWR nuclear plants. This paper deals with two types of analyses including logical argumentation and simulation. Crack arrest in networks is demonstrated due to the presence of two cracks of the same depth in the network. This identical depth may be proved assuming that mean stress acts only on crack opening and that cracks are fully open during the load cycle before arrest. Weld residual stresses (WRS) are obtained by an axisymmetric simulation of welding on a tube with a chamfer. Axisymmetric and 3D parametric studies of crack growth on: representative sequences for variable amplitude thermal loading, fatigue crack growth threshold (FCGT), permanent mean stress, cyclic counting methods and WRS, are performed with Code-Aster software using XFEM methodology. The following results are obtained on crack depth versus time: the effect of WRS on crack growth cannot be determined by the initial WRS field in absence of crack, but by the associated stress intensity factor. Moreover the relation between crack arrest depth and WRS is analyzed. In the absence of FCGT Paris’s law may give a significant over-estimation of crack depth even if amplitudes of loading smaller than FCGT have not been considered. Appropriate depth versus time may be obtained using different values of FCGT, but axisymmetric simulations do not really show a possibility of arrest for shallow cracks in

  5. Residual stresses in a weldment of pressure vessel steel

    International Nuclear Information System (INIS)

    Gott, K.E.

    1978-01-01

    A study was made of the distribution of residual stresses around a typical weld from a light water reactor pressure vessel by an X-ray double-exposure camera technique. So that the magnitude, sign, and distribution of the residual stresses were as similar as possible to those found in practice, a wide, full-thickness specimen of A533B Cl 1 steel containing a submerged-arc weld was stress-relief annealed. To obtain a three-dimensional distribution of the stresses the specimen was examined at different levels through the thickness. Following the removal of material by milling, the specimen surface was electropolished to free it from cold work. Corrections have been made to take into account specimen relaxation. To completely define the original stress system it is desirable also to measure the change in curvature on removing a layer of material. Unless this is done assumptions must be made which complicate the calculations unnecessarily. This became apparent after the experimental work was completed. In the centre of the plate the methods of correction which can be used are sensitive to errors in the measurements. The corrected results show that the dominant residual stress is perpendicular to the weld. It is positive at the surfaces and negative in the centre of the plate. The maximum value can reach the yield stress. The residual stresses in the weld metal can locally vary considerably: from 100 to 350N/mm 2 over a distance of 5mm. Such large variations have been found to coincide with the heat-affected zones of the individual weld runs. (author)

  6. Modelling and experimental characterisation of a residual stress field in a ferritic compact tension specimen

    International Nuclear Information System (INIS)

    Wenman, M.R.; Price, A.J.; Steuwer, A.; Chard-Tuckey, P.R.; Crocombe, A.

    2009-01-01

    The aim of the work is to elucidate the influence of plasticity behaviour on the residual stress field in a ferritic reactor pressure vessel steel. To this end, we investigate two compressively pre-loaded compact tension (CT) specimens to generate a mechanical residual stress field. One specimen was subsequently pre-cracked by fatigue before both specimens were measured using high-energy synchrotron X-ray diffraction. A fine grain size microstructure (∼5-10 μm grain size) allowed a small X-ray beam slit size and therefore gauge volume. The results provide an excellent data set for validation of finite element (FE) modelling predictions against which they have been compared. The results of both mechanical testing and modelling suggest that the use of a combined hardening model is needed to accurately predict the residual stress field present in the specimen after pre-loading. Some discrepancy between the modelled crack tip stress values and those found by X-ray diffraction remain which can be partly explained by volume averaging effects in the presence of very high stress/strain gradients.

  7. Modelling and experimental characterisation of a residual stress field in a ferritic compact tension specimen

    Energy Technology Data Exchange (ETDEWEB)

    Wenman, M.R., E-mail: m.wenman@imperial.ac.u [Department of Materials, Imperial College London, London SW7 2AZ (United Kingdom); Price, A.J. [Faculty of Engineering and Physical Sciences (J5), University of Surrey, Guildford GU2 7XH (United Kingdom); Steuwer, A. [ESS Scandinavia, Stora Algatan 4, 22350 Lund (Sweden) and Nelson Mandela Metropolitan University, Port Elizabeth 6031 (South Africa); Chard-Tuckey, P.R. [Nuclear Department, Defence College of Management and Technology, HMS Sultan, Gosport, Hants PO12 3BY (United Kingdom); Crocombe, A. [Faculty of Engineering and Physical Sciences (J5), University of Surrey, Guildford GU2 7XH (United Kingdom)

    2009-12-15

    The aim of the work is to elucidate the influence of plasticity behaviour on the residual stress field in a ferritic reactor pressure vessel steel. To this end, we investigate two compressively pre-loaded compact tension (CT) specimens to generate a mechanical residual stress field. One specimen was subsequently pre-cracked by fatigue before both specimens were measured using high-energy synchrotron X-ray diffraction. A fine grain size microstructure (approx5-10 mum grain size) allowed a small X-ray beam slit size and therefore gauge volume. The results provide an excellent data set for validation of finite element (FE) modelling predictions against which they have been compared. The results of both mechanical testing and modelling suggest that the use of a combined hardening model is needed to accurately predict the residual stress field present in the specimen after pre-loading. Some discrepancy between the modelled crack tip stress values and those found by X-ray diffraction remain which can be partly explained by volume averaging effects in the presence of very high stress/strain gradients.

  8. Effects of LSP on micro-structures and residual stresses in a 4 mm CLAM steel weld joints

    Energy Technology Data Exchange (ETDEWEB)

    Chen, Xizhang, E-mail: chenxizhang@wzu.edu.cn [School of Mechanical and Electrical Engineering, Wenzhou University., Wenzhou 325035 (China); School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu (China); Fang, Yuanyuan [School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu (China); Zhang, Shuyan; Kelleher, Joe F. [ISIS, Rutherford Appleton Laboratory, Chilton, Didcot OX11 0QX (United Kingdom); Zhou, Jianzhong [School of Mechanical Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu (China)

    2015-05-15

    The effects of laser shock processing (LSP) on the distribution of residual stress and micro-structure of China Low Activation Martensitic (CLAM) steel weldment were investigated via neutron diffraction and optical microscope (OM). A pair of 4 mm CLAM steel plates joined by GTA welding. Special attention is paid to the generation of high level compressive residual stresses introduced by LSP. Residual stress in longitudinal, normal and transversal direction at weldment surface and longitudinal stress through thickness are evaluated via neutron diffraction. Compressive residual stress after LSP occurred at more than 90% areas within the weld joint, it is almost double the areas of compressive stress compare to weldment surface before LSP. The maximum compressive normal residual stress becomes to −183 MPa after LSP from −63 MPa before LSP. The Modification of surface micro-structures including weld zone (WZ), heat affected zone (HAZ) and base metal (BM) are also discussed. Results to date demonstrate that laser shock processing has been a great potential method for the improvement of mechanical performance of components.

  9. Numerical simulation of residual stress in piping components at Framatome-ANP

    International Nuclear Information System (INIS)

    Gilies, P.; Franco, C.; Cipiere, M.-F.; Ould, P.

    2005-01-01

    Numerous manufacturing processes induce residual stresses and distortions in piping components and associated welds: quenching of cast pipings, machining and welding. In Pressurized Water Reactors, most of the components have a large thickness for sustaining pressure and distortions are a minor source of concern. This is not the case for residual stresses which may have a strong influence on several type of damage such as fatigue, corrosion, brittle fracture. In low toughness components, residual stress fields may contribute to ductile tearing initiation. These potential damages are mitigated after welding by stress relief heat treatment, which is applied in a systematic manner to ferritic components of the primary system in nuclear reactors. This treatment is not applied on austenitic piping for which the heat treatment temperature is limited due to the risk of sensitization and residual stresses are difficult to eliminate completely. Since on site measurements are costly and difficult to perform, numerical simulation appears to be an attractive tool for estimating residual stress distributions. Framatome-ANP is working on modelling manufacturing processes with that purpose in mind. This paper presents three kinds of applications illustrating efforts on welding, quenching and machining simulation. First a comparison is shown between computations and measurements of residual stress induced by welding of a dissimilar weld metal junction. Then numerical simulations of quenching of a cast stainless steel nozzle are presented. Finally quenching followed by machining and grinding of this cast component are considered in a full simulation of the manufacturing process. Computed distortions and residual stresses are compared with experimental measurements at different stages of the manufacturing process. (authors)

  10. Mapping residual stress by ultrasonic tomography

    International Nuclear Information System (INIS)

    Hildebrand, B.P.; Harrington, T.P.

    1979-01-01

    It is known that internal stress concentrations can give rise to microcracks which then grow when the structure is subjected to external forces. It has also been found that the velocity of sound is altered as it propagates through a region of stress. In this paper a technique called Computer-Assisted Tomography (CAT) is discussed and an application that provides pictures of stress fields is described. The results of both simulated and experimental models used to evaluate the technique are reported. It is concluded that the CAT approach has great potential for locating and mapping residual stress in metals. (author)

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

    International Nuclear Information System (INIS)

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

    2016-01-01

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

  12. Fatigue life estimation of welded components considering welding residual stress relaxation and its mean stress effect

    International Nuclear Information System (INIS)

    Han, Seung Ho; Han, Jeong Woo; Shin, Byung Chun; Kim, Jae Hoon

    2003-01-01

    The fatigue life of welded joints is sensitive to welding residual stress and complexity of their geometric shapes. To predict the fatigue life more reasonably, the effects of welding residual stress and its relaxation on their fatigue strengths should be considered quantitatively, which are often regarded to be equivalent to the effects of mean stresses by external loads. The hot-spot stress concept should be also adopted which can reduce the dependence of fatigue strengths for various welding details. Considering the factors mentioned above, a fatigue life prediction model using the modified Goodman's diagram was proposed. In this model, an equivalent stress was introduced which is composed of the mean stress based on the hot-spot stress concept and the relaxed welding residual stress. From the verification of the proposed model to real welding details, it is proved that this model can be applied to predict reasonably their fatigue lives

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

    Science.gov (United States)

    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.

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

    Directory of Open Access Journals (Sweden)

    Yang Hua

    2018-05-01

    Full Text Available 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.

  15. Measurement of residual stresses in welded sample of dissimilar materials

    International Nuclear Information System (INIS)

    Mansur, Tanius Rodrigues; Gomes, Paulo de Tarso Vida; Scaldaferri, Denis Henrique Bianchi; Martins, Geraldo Antonio Scoralick; Atanazio Filho, Nelson do Nascimento

    2008-01-01

    The welding of dissimilar metals has several applications in the industry. Especially in the nuclear industry, this joint type, common between carbon steel and stainless steel, it is always reason of analysis and special cares tends in view the need to maintain the integrity of the equipment. Residual stresses are introduced in the material as a result of processes as welding, machining, sanding and polishing that can to produce deformation in the proximities of the surface of the material. Residual compressive stresses can be introduced in the material through the jetting process (bombardment of the surface for small glass spheres, dry sand or steel). That procedure allows a fine subsurface layer to suffer yielding, compressing the superficial layer and reducing the formation of areas of concentration of traction stresses, increasing the resistance of the material to the fatigue. The welding process introduces residual stresses due to the geometry resulting from the fusion of the material welded and of the heterogeneous cooling. Besides the microstructural alteration and chemical composition of the material in the affected area for the heat, introduced by the welding, it is also had the effect of the discontinuity of the passes and the formation of bubbles and emptiness that can contribute to the cracks nucleation, reducing the resistance to the fatigue. In the great majority of the times residual stresses are harmful and there are many documented cases which US these stresses went predominant factors for the failure for fatigue. A particularly dangerous aspect of the residual stresses is that their presence is not usually observed, what usually happens with an applied load to the structure. The knowledge of the surface residual stresses is important to predict the emergence of failure when the component or structure is requested. In nuclear power plants it is common to welding of piping of stainless steels with mouthpieces of carbon steel of pressure vases of

  16. Application of X-rays and Synchrotron X Rays to Residual Stress Evaluation Near Surfaces

    International Nuclear Information System (INIS)

    Pyzalla, Anke

    1999-01-01

    A nondestructive residual stress analysis can be performed using diffraction methods. The easiest accessible radiation is characteristic X radiation that has a penetration depth of ∼10 microm suitable for the determination of the residual stresses in near-surface layers. Special techniques have been developed, e.g., with respect to in situ analyses of the stress state in oxide layers and the residual stress analysis in coarse grained zones of steel welds or annealed Ni-base alloys. Depending on the size of the gauge volume, neutron diffraction can provide information at depths of tens of millimetres of steel and many tens of millimetres of Al. An alternative to the use of the characteristic synchrotron radiation is the use of a high-energy polychromatic beam in an energy dispersive arrangement, which gives access to higher penetration depths at still gauge volumes as small as 100 microm x 100 microm x 1 mm in steel rods of 15-mm diameter. The combination of neutrons with conventional X rays and monochromatic and polychromatic synchrotron radiation allows for a comprehensive investigation of the phase composition, the texture, and the residual stresses

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

    International Nuclear Information System (INIS)

    Shack, W.J.

    1985-02-01

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

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

    International Nuclear Information System (INIS)

    Wang, Jing; Feng, Qibo

    2015-01-01

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

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

    Science.gov (United States)

    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.

  20. Residual stress measurement of the jacket material for ITER coil by neutron diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Tsuchiya, Yoshinori [Japan Atomic Energy Research Inst., Tokai, Ibaraki (Japan). Tokai Research Establishment

    1998-03-01

    Nickel-Iron based super alloy INCOLOY 908 is used for the jacket of a central solenoid coil (CS coil) of the International Thermonuclear Experimental Reactor (ITER). INCOLOY 908, however, has a possibility of fracture due to Stress Accelerated Grain Boundary Oxidation (SAGBO) under a tensile residual stress beyond 200MPa. Therefore it is necessary to measure the residual stress of the jacket to avoid SAGBO. We performed residual stress measurement of the jacket by neutron diffraction using the neutron diffractometer for residual stress analysis (RESA) installed at JRR-3M in JAERI. A sample depth dependence of internal strain was obtained from the (111) plane spacing. A residual stress distribution was calculated from the strain using Young`s modulus and Poisson`s ratio that were evaluated by a tensile test with neutron diffraction. The result shows that the tensile residual stress exceeds 200MPa of the SAGBO condition in some regions inside the jacket. (author)

  1. Residual stress distribution in carbon steel pipe welded joint measured by neutron diffraction

    International Nuclear Information System (INIS)

    Hayashi, Makoto; Ishiwata, Masayuki; Morii, Yukio; Minakawa, Nobuaki

    2000-01-01

    In order to estimate crack growth behavior of fatigue and stress corrosion cracking in pipes, the residual stress distribution near the pipe weld region has to be measured through the wall thickness. Since the penetration depth of neutron is deep enough to pass through the thick pipe wall, the neutron diffraction technique for the residual stress measurement is effective for this purpose. At the first step the residual stress distribution near the weld region in a butt-welded carbon steel pipe was measured by the neutron diffraction. Significant stresses extended only to a distance of 30 mm from the center of the weld. The major tensile stresses occurred in the hoop direction in the fusion and heat affected zones of the weldment, and they attained a level greater than 200 MPa through the thickness. While the axial residual stress at the inside surface was 50 MPa, the stress at the outside surface was -100 MPa. The comparison of residual stress distributions measured by the neutron diffraction, the X-ray diffraction and the strain gauge method reveals that the neutron diffraction is the most effective for measuring the residual stress inside the structural components. (author)

  2. RESIDUAL STRESS MEASUREMENTS AND STRUCTURAL INTEGRITY IMPLICATIONS FOR SELECTIVE LASER MELTED TI-6AL-4V

    Directory of Open Access Journals (Sweden)

    Knowles, C. R.

    2012-11-01

    Full Text Available Selective laser melting (SLM of Ti-6Al-4V has significant potential in the aerospace and biotechnology industries. SLM employs a focused laser beam to melt successive layers of metallic powder into complex components. This process can result in the generation of high thermally-induced residual stresses. These residual stresses, together with micro-flaws/ pores from the inherent fabrication process, may lead to premature fatigue crack initiation and propagation at relatively low cyclic stresses. The hole-drilling strain gauge method was used to evaluate residual stresses within SLM Ti-6Al-4V specimens, with the intention of understanding the associated mechanisms for the successful application of SLM Ti-6Al-4V in industry.

  3. Residual stress in TI6AL4V objects produced by direct metal laser sintering

    Directory of Open Access Journals (Sweden)

    Van Zyl, Ian

    2016-12-01

    Full Text Available Direct Metal Laser Sintering produces 3D objects using a layer-by- layer method in which powder is deposited in thin layers. Laser beam scans over the powder fusing powder particles as well as the previous layer. High-concentration of laser energy input leads to high thermal gradients which induce residual stress within the as- built parts. Ti6Al4V (ELI samples have been manufactured by EOSINT M280 system at prescribed by EOS process-parameters. Residual stresses were measured by XRD method. Microstructure, values and directions of principal stresses inTi6Al4V DMLS samples were analysed.

  4. Residual stress evaluation and fatigue life prediction in the welded joint by X-ray diffraction

    International Nuclear Information System (INIS)

    Yoo, Keun Bong; Kim, Jae Hoon

    2009-01-01

    In the fossil power plant, the reliability of the components which consist of the many welded parts depends on the quality of welding. The residual stress is occurred by the heat flux of high temperature during weld process. This decreases the mechanical properties as the strength of fatigue and fracture or occurs the stress corrosion cracking and fatigue fracture. The residual stress of the welded part in the recently constructed power plants has been the cause of a variety of accidents. The objective of this study is measurement of the residual stress by X-ray diffraction method and to estimate the feasibility of this application for fatigue life assessment of the high-temperature pipeline. The materials used for the study is P92 steel for the use of high temperature pipe on super critical condition. The test results were analyzed by the distributed characteristics of residual stresses and the Full Width at Half Maximum intensity (FWHM) in x-ray diffraction intensity curve. Also, X-ray diffraction tests using specimens simulated low cycle fatigue damage were performed in order to analyze fatigue properties when fatigue damage conditions become various stages. As a result of X-ray diffraction tests for specimens simulated fatigue damages, we conformed that the ratio of the FWHM due to fatigue damage has linear relationship with fatigue life ratio algebraically. From this relationships, it was suggested that direct expectation of the life consumption rate was feasible.

  5. Modeling of plates with multiple anisotropic layers and residual stress

    DEFF Research Database (Denmark)

    Engholm, Mathias; Pedersen, Thomas; Thomsen, Erik Vilain

    2016-01-01

    Usually the analytical approach for modeling of plates uses the single layer plate equation to obtain the deflection and does not take anisotropy and residual stress into account. Based on the stress–strain relation of each layer and balancing stress resultants and bending moments, a general...... multilayered anisotropic plate equation is developed for plates with an arbitrary number of layers. The exact deflection profile is calculated for a circular clamped plate of anisotropic materials with residual bi-axial stress.From the deflection shape the critical stress for buckling is calculated......, and an excellent agreement between the two models is seen with a relative difference of less than 2% for all calculations. The model was also used to extract the cell capacitance, the parasitic capacitance and the residual stress of a pressure sensor composed of a multilayered plate of silicon and silicon oxide...

  6. Residual stresses generated in F-522 steel by different machining processes

    International Nuclear Information System (INIS)

    Gracia-Navas, V.; Ferreres, I.; Maranon, J. A.; Garcia-Rosales, C.; Gil-Sevillano, J.

    2005-01-01

    Machining operations induce plastic deformation and heat generation in the near surface area of the machined part, giving rise to residual stresses. Depending on their magnitude and sign, these stresses can be detrimental or beneficial to the service life of the part. The final stress state depends on the machining process applied, as well as on the machining parameters. Therefore, the establishment of adequate machining guidelines requires the measurement of the residual stresses generated both at the surface and inside the material. in this work, the residual stresses generated in F-522 steel by two hard turning (conventional and laser assisted) and two grinding (production and finishing) processes were measured by X-ray diffraction. Additionally, depth profiles of the volume fraction of retained austenite, microstructure and nano hardness were obtained in order to correlate those results with the residual stress state obtained for each machining process. It has been observed that turning generates tensile stresses in the surface while grinding causes compressive stresses. Below the surface grinding generates weak tensile or nearly null stresses whereas turning generates strong compressive stresses. These results show that the optimum mechanising process (disregarding economical considerations) implies the combination of turning plus elimination of a small thickness by final grinding. (Author) 19 refs

  7. The residual stress evaluation for expansion process of steam generator tubes

    International Nuclear Information System (INIS)

    King, C.-S.; Lee, S.-C.; Shim, D.-N.

    2004-01-01

    The reliability of a nuclear power plant is affected by the reliability of steam generator tube and the reliability of steam generator tube is affected by stress corrosion cracking(SCC). Many steam generator tubes were experiencing stress corrosion cracking and stress corrosion cracking is affected material characteristics, corrosive environments and added stresses. The added stresses have the manufacturing stresses and operating stresses, the manufacturing stresses include the residual stresses generating in the tube manufacture and tube expanding procedure. We will investigate for influence which affected to residual stresses with tube plastic deformation method and measurement region. (author)

  8. Effect of residual stress on fatigue crack propagation at 200 C in a welded joint austenitic stainless steel - ferritic steel

    International Nuclear Information System (INIS)

    Zahouane, A.I.; Gauthier, J.P.; Petrequin, P.

    1988-01-01

    Fatigue resistance of heterogeneous welded joints between austenitic stainless steels and ferritic steels is evaluated for reactor components and more particularly effect of residual stress on fatigue crack propagation in a heterogeneous welded joint. Residual stress is measured by the hole method in which a hole is drilled through the center of a strain gage glued the surface of the materials. In the non uniform stress field a transmissibility function is used for residual stress calculation. High compression residual stress in the ferritic metal near the interface ferritic steel/weld slow down fatigue crack propagation. 5 tabs., 15 figs., 19 refs [fr

  9. Investigation of surface residual stress profile on martensitic stainless steel weldment with X-ray diffraction

    Directory of Open Access Journals (Sweden)

    I.I. Ahmed

    2018-04-01

    Full Text Available The development of residual stresses during fabrication is inevitable and often neglected with dire consequences during the service life of the fabricated components. In this work, the surface residual stress profile following the martensitic stainless steel (MSS pipe welding was investigated with X-ray diffraction technique. The results revealed the presence of residual stresses equilibrated across the weldment zones. Tensile residual stress observed in weld metal was balanced by compressive residual stresses in the parent material on the opposing sides of weld metal. Keywords: Residual stress, Weld, Stainless steel, X-ray, HAZ

  10. Study by X-ray diffraction and mechanical analysis of the residual stress generation during thermal spraying

    International Nuclear Information System (INIS)

    Pina, J.; Dias, A.; Lebrun, J.L.

    2003-01-01

    Thermally sprayed coatings are formed by the deposition of molten or partially molten particles, propelled onto a substrate where they impact, spread and solidify rapidly. Residual stresses are expected within the sprayed deposit as a consequence of the release of thermal and kinetic energies. A wide range of materials and two spraying techniques are considered in this study, namely atmospheric plasma spraying (APS) and high-velocity oxygen fuel. Stresses were determined by the X-ray diffraction (XRD) method. The results were compared with those calculated by mechanical analysis of stress relief in coatings detached from the substrate. Comparison of the results for adherent and free-standing coatings shows that the residual stress state can be resolved in terms of the components suggested by models that propose two stages of stress generation: quenching stresses and secondary-cooling stresses. The in-depth distribution of residual stresses, through the coating thickness, is discussed in terms of the nature of the coating system

  11. Residual stress in polyethylene pipes

    Czech Academy of Sciences Publication Activity Database

    Poduška, Jan; Hutař, Pavel; Kučera, J.; Frank, A.; Sadílek, J.; Pinter, G.; Náhlík, Luboš

    2016-01-01

    Roč. 54, SEP (2016), s. 288-295 ISSN 0142-9418 R&D Projects: GA MŠk LM2015069; GA MŠk(CZ) LQ1601 Institutional support: RVO:68081723 Keywords : polyethylene pipe * residual stress * ring slitting method * lifetime estimation Subject RIV: JL - Materials Fatigue, Friction Mechanics Impact factor: 2.464, year: 2016

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

    Science.gov (United States)

    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

  13. Stress and Fatigue Life Modeling of Cannon Breech Closures Including Effects of Material Strength and Residual Stress

    National Research Council Canada - National Science Library

    Underwood, John

    2000-01-01

    ...; overload residual stress. Modeling of applied and residual stresses at the location of the fatigue failure site is performed by elastic-plastic finite element analysis using ABAQUS and by solid...

  14. Residual stress evaluation in brittle coatings using indentation technique combined with in-situ bending

    International Nuclear Information System (INIS)

    Futakawa, Masatoshi; Steinbrech, R.W.; Tanabe, Yuji; Hara, Toshiaki

    2000-01-01

    The indentation crack length approach was adopted and further elaborated to evaluate residual stress and toughness of the brittle coatings: two kinds of glass coatings on steel. The influence of the residual stress on indentation cracking was examined in as-received coating condition and by in-situ superimposing a counteracting tensile stress. For purpose of providing reference toughness values stress-free pieces of separated coating material have also been examined. Thus results of the two complementary sets of experiments were assumed to prove self-consistently toughness and residual stress data of the coating. In particular, the in-situ bending of specimen in combination with the indentation test allowed us to vary deliberately the residual stress situation in glass coating. Thus experiments which utilized the combination of bending test and micro-indentation were introduced as a method to provide unambiguous information about residual compressive stress. Toughness and residual compressive stress of glass coatings used in this study were 0.46-0.50 MPa·m 1/2 and 94-111 MPa, respectively. Furthermore, a thermoelastic calculation of the residual compressive stress was performed and it is found that the value of residual compressive stress at coating surface of specimen was 90-102 MPa. (author)

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

    Science.gov (United States)

    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.

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

    Science.gov (United States)

    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.

  17. Finite element analysis of residual stress in the welded zone of a ...

    Indian Academy of Sciences (India)

    Unknown

    The distribution of the residual stress in the weld joint of HQ130 grade high strength steel was in- vestigated by ... was adopted in this work to find out the instantaneous distribution of .... welding zone of high strength steel are related to the for-.

  18. Significance of residual stress on fatigue properties of welded pipes

    International Nuclear Information System (INIS)

    Ohta, A.; Maeda, Y.; Kanao, M.

    1984-01-01

    The mean stress effect on the fatigue properties of two kinds of welded pipes was investigated in cantilever bending. The fatigue strength changed with the mean stress on fillet welded pipes, but did not change on butt welded pipes. The fatigue crack initiated from the toe of weld on the outer surface of fillet welded pipes and from the undercut on the inner surface of butt welded pipes. The measurement of the fatigue crack propagation rate and the residual stress distribution through the thickness of pipe revealed that the difference in the fatigue properties between fillet and butt welded pipes arose from the weld-induced residual stress, tension on the inner surface and compression on the outer surface. It is suggested that the production of compressive residual stress along the inner surface would be an effective means for improving the fatigue strength of butt welded pipes. (author)

  19. Comparison of Measured Residual Stress in an Extra Thick Multi-pass Weld Using Neutron Diffraction Method and Inherent Strain Method

    International Nuclear Information System (INIS)

    Park, JeongUng; An, GyuBaek; Woo, Wan Chuck

    2015-01-01

    With the increase of large-scale containership, a large amount of high-strength steels with extra thick plates is being extensively used. The welding stress existing in the extra thick welded plates has a significant effect on the integrity of the component in terms of brittle fracture and fatigue behavior. It has been reported that welding residual stress distribution in an extra thick plate can affect the propagation path of the crack. Therefore, it is important to measure the distribution of welding residual stresses for the reliable design of the welded structures. So far various researches have been carried out for the determination of residual stresses on the surface of steels. In this paper, the total residual stresses in the 70 mm thick multipass FACW butt joint were measured by integrating initial stress into ISM. Concretely, two methods named as initial stress integrated ISM and initial inherent strain integrated ISM were employed to determine the total residual stresses. Furthermore, the distributions of residual stresses were compared with the results of the Neutron Diffraction Method(NDM). In order to measure the three dimensional residual stresses in the welded joint with initial stresses existing before welding, initial stress integrated ISM and initial inherent strain integrated ISM were developed. The residual stresses in 70 mm-thick butt joint by flux cored arc welding were carried out with a good accuracy using the two developed methods. The residual stresses in welded joint using both initial stress integrated ISM and initial inherent strain integrated ISM agreed well with the results measured by Neutron Diffraction Method. This suggests that the integrated ISM is a reliable method for residual stress measurement if initial stress existed

  20. A Study on the Residual Stress Improvement of PWSCC(Primary Water Stress Corrosion Cracking) in DMW(Dissimilar Metal Weld)

    International Nuclear Information System (INIS)

    Kang, Sung Sik; Kim, Seok Hun; Lee, Seung Gun; Park, Heung Bae

    2010-01-01

    Since 2000s, most of the cracks are found in welds, especially in (DMW) dissimilar metal welds such as pressurizer safety relief nozzle, reactor head penetration, reactor bottom mounted instrumentation (BMI), and reactor nozzles. Even the cracks are revealed as a primary water stress corrosion cracking (PWSCC), it is difficult to find the cracks by current non destructive examination. The PWSCC is occurred by three incident factors, such as susceptible material, environmental corrosive condition, and welding residual stress. If one of the three factors can be erased or decreased, the PWSCC could be prevented. In this study, we performed residual stress analysis for DMW and several residual stress improvement methods. As the preventive methods of PWSCC, we used laser peening(IP) method, inlay weld(IW) method, and induction heating stress improvement(IHSI) method. The effect of residual stress improvement for preventive methods was compared and discussed by finite element modeling and residual stress of repaired DMW

  1. Residual stress measurement method in MEMS microbeams using frequency shift data

    International Nuclear Information System (INIS)

    Somà, Aurelio; Ballestra, Alberto

    2009-01-01

    The dynamical behaviour of a set of gold microbeams affected by residual stress has been studied. Experimental frequency shift curves were obtained by increasing the dc voltage applied to the specimens. Comparison with different analytical and numerical models has been carried out in order to identify both analytical and finite element models in the presence of residual stress. Residual strain and stress, due to the fabrication process, have been widely reported in the literature in both out-of-plane microcantilevers and clamped–clamped microbeams by using mainly the value of pull-in voltage and static deflection data. In the case of a microcantilever, an accurate modelling includes the effect of the initial curvature due to microfabrication. In double-clamped microbeams, a pre-load applied by tensile stress is considered. A good correspondence is pointed out between measurements and numerical models so that the residual stress effect can be evaluated for different geometrical configurations

  2. Finite element analysis of residual stress in plasma-sprayed ceramic

    International Nuclear Information System (INIS)

    Mullen, R.L.; Hendricks, R.C.; McDonald, G.

    1985-01-01

    Residual stress in a ZrO 2 -Y 2 O 3 ceramic coating resulting from the plasma spraying operation is calculated. The calculations were done using the finite element method. Both thermal and mechanical analysis were performed. The resulting residual stress field was compared to the measurements obtained by Hendricks and McDonald. Reasonable agreement between the predicted and measured moment occurred. However, the resulting stress field is not in pure bending

  3. The effects of location, thermal stress, and residual stress on corner cracks in nozzles with cladding

    International Nuclear Information System (INIS)

    Besuner, P.M.; Cohen, L.M.; McLean, J.L.

    1977-01-01

    The stress intensity factors (Ksub(I)) for corner cracks in a boiling water reactor feedwater nozzle with stainless steel cladding are obtained for loading by internal pressure, and a fluid quench in the nozzle. Conditions with and without residual stress in the component are considered. The residual stress is simulated by means of a reference temperature change. The stress distribution for the uncracked structure is obtained from a three-dimensional finite element model. A three-dimensional influence function (IF) method, in conjunction with the boundary-integral equation method for structural analysis is employed to compute Ksub(I) values from the uncracked structure's stress distribution. It is concluded that the effects on Ksub(I) of location, thermal stresses, and residual stresses are significant and generally too complex to evaluate without advanced numerical procedures. The ulilized combination of finite element analysis of the uncracked structure and three-dimensional influence function analysis of the cracked structure is demonstrated and endorsed. (Auth.)

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

    Science.gov (United States)

    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

  5. Investigation of the Residual Stress State in an Epoxy Based Specimen

    DEFF Research Database (Denmark)

    Baran, Ismet; Jakobsen, Johnny; Andreasen, Jens Henrik

    2015-01-01

    Abstract. Process induced residual stresses may play an important role under service loading conditions for fiber reinforced composite. They may initiate premature cracks and alter the internal stress level. Therefore, the developed numerical models have to be validated with the experimental...... observations. In the present work, the formation of the residual stresses/strains are captured from experimental measurements and numerical models. An epoxy/steel based sample configuration is considered which creates an in-plane biaxial stress state during curing of the resin. A hole drilling process...... material models, i.e. cure kinetics, elastic modulus, CTE, chemical shrinkage, etc. together with the drilling process using the finite element method. The measured and predicted in-plane residual strain states are compared for the epoxy/metal biaxial stress specimen....

  6. Stresses and residual stresses optical measurements systems evaluation; Avaliacao de sistemas opticos de medicao de tensoes e tensoes residuais em dutos

    Energy Technology Data Exchange (ETDEWEB)

    Peixoto Filho, Flavio Tito; Goncalves Junior, Armando Albertazzi [Universidade Federal de Santa Catarina (UFSC), Florianopolis, SC (Brazil). Lab. de Metrologia e Automatizacao (LABMETRO)

    2004-07-01

    There is always a constant concern about the pipelines' integrity. An important control parameter is the level of total mechanical stresses acting over the pipeline. However, the loading and residual stresses acting on a pipeline are not measured in the field as much as necessary. Technical difficulties and the high cost of the nowadays techniques and the hostile measurement conditions are the main reason for that. An alternative method has been developed at the Universidade Federal de Santa Catarina (UFSC) since 1992. A new optical measurement device is used to measure strains, mechanical stresses and residual stresses acting over the structure. A metrological and functional evaluation of this system is the main focus of this paper. (author)

  7. Effects of location, thermal stress and residual stress on corner cracks in nozzles with cladding

    International Nuclear Information System (INIS)

    McLean, J.L.; Cohen, L.M.; Besuner, P.M.

    1979-01-01

    The stress intensity factors (K 1 ) for corner cracks in a boiling water reactor feedwater nozzle with stainless steel cladding are obtained for loading by internal pressure and a fluid quench in the nozzle. Conditions both with and without residual stress in the component are considered. The residual stress is simulated by means of a reference temperature change. The stress distribution for the uncracked structure is obtained from a three-dimensional finite element model. A three-dimensional influence function (IF) method, in conjunction with the boundary-integral equation method for structural analysis, is employed to compute K 1 values from the uncracked stress distribution. For each type of loading K 1 values are given for cracks at 15 nozzle locations and for 6 crack depths. Reasonable agreement is noted between calculated and previously published pressure-induced K 1 values. Comparisons are made to determine the effect on K 1 of crack location, thermal stress and residual stress, as compared with pressure stress. For the thermal transient it is shown that K 1 for small crack depths is maximised early in the transient, while K 1 for large cracks is maximised later under steady state conditions. Computation should, therefore, be made for several transient time points and the maximum K 1 for a given crack depth should be used for design analysis. It is concluded that the effects on K 1 of location, thermal stresses and residual stresses are significant and generally too complex to evaluate without advanced numerical procedures. The utilised combination of finite element analysis of the uncracked structure and three-dimensional influence function analysis of the cracked structure is demonstrated and endorsed. (author)

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

    International Nuclear Information System (INIS)

    Zhu Lina; Xu Binshi; Wang Haidou; Wang Chengbiao

    2010-01-01

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

  9. Estimation of residual stress in cold rolled iron-disks from strain measurements on the high resolution Fourier diffractometer

    International Nuclear Information System (INIS)

    Aksenov, V.L.; Balagurov, A.M.; Taran, Yu.V.

    1995-01-01

    The results of estimating residual stresses in cold rolled iron disks by measurements with the high resolution Fourier diffractometer (HRFD) at the IBR-2 pulsed reactor are presented. These measurements were made for calibration of magnetic and ultrasonic measurements carried out at the Fraunhofer-Institute for Nondestructive Testing in Saarbrucken (Germany). The tested objects were cold rolled steel disks of 2.5 mm thickness and diameter of about 500 mm used for forming small, gas pressure tanks. Neutron diffraction experiments were carried out at the scattering angle 2θ=+152 d eg with resolution Δd/d=1.5·10 -3 . The gauge volume was chosen according to the magnetic measurements lateral resolution 20x20 mm 2 . In the nearest future the neutron diffraction measurements with cold rolled iron disks at the scattering angle 2θ=±90 0 are planned. Also the texture analysis will be included in the Rietveld refinement procedure for more correct calculation of residual stress fields in the cold rolled materials. 8 refs., 10 figs., 1 tab

  10. Neutron diffraction measurements of residual stress in additively manufactured stainless steel

    International Nuclear Information System (INIS)

    Brown, D.W.; Bernardin, J.D.; Carpenter, J.S.; Clausen, B.; Spernjak, D.; Thompson, J.M.

    2016-01-01

    Charpy test specimens were additively manufactured (AM) on a single stainless steel plate from a 17–4 class stainless steel using a powder-bed, laser melting technique on an EOS M280 direct metal laser sintering (DMLS) machine. Cross-hatched mesh support structures for the Charpy test specimens were varied in strut width and density to parametrically study their influence on the build stability and accuracy as the DMLS process has been known to generate parts with large amounts of residual stress. Neutron diffraction was used to profile the residual stresses in several of the AM samples before and after the samples were removed from the support structure for the purpose of determining residual stresses. The residual stresses were found to depend very little on the properties of the support structure over the limited range studied here. The largest stress component was in the long direction of each of the samples studied and was roughly 2/3 of the yield stress of the material. The stress field was altered considerably when the specimen was removed from the support structure. It was noted in this study that a single Charpy specimen developed a significant tear between the growth plate and support structure. The presence of the tear in the support structure strongly affected the observed stress field: the asymmetric tear resulted in a significantly asymmetric stress field that propagated through removal of the sample from the base plate. The altered final residual stress state of the sample as well as its observed final shape indicates that the tear initiated during the build and developed without disrupting the fabrication process, suggesting a need for in-situ monitoring.

  11. Neutron diffraction measurements of residual stress in additively manufactured stainless steel

    Energy Technology Data Exchange (ETDEWEB)

    Brown, D.W.; Bernardin, J.D.; Carpenter, J.S.; Clausen, B.; Spernjak, D.; Thompson, J.M.

    2016-12-15

    Charpy test specimens were additively manufactured (AM) on a single stainless steel plate from a 17–4 class stainless steel using a powder-bed, laser melting technique on an EOS M280 direct metal laser sintering (DMLS) machine. Cross-hatched mesh support structures for the Charpy test specimens were varied in strut width and density to parametrically study their influence on the build stability and accuracy as the DMLS process has been known to generate parts with large amounts of residual stress. Neutron diffraction was used to profile the residual stresses in several of the AM samples before and after the samples were removed from the support structure for the purpose of determining residual stresses. The residual stresses were found to depend very little on the properties of the support structure over the limited range studied here. The largest stress component was in the long direction of each of the samples studied and was roughly 2/3 of the yield stress of the material. The stress field was altered considerably when the specimen was removed from the support structure. It was noted in this study that a single Charpy specimen developed a significant tear between the growth plate and support structure. The presence of the tear in the support structure strongly affected the observed stress field: the asymmetric tear resulted in a significantly asymmetric stress field that propagated through removal of the sample from the base plate. The altered final residual stress state of the sample as well as its observed final shape indicates that the tear initiated during the build and developed without disrupting the fabrication process, suggesting a need for in-situ monitoring.

  12. Comparison of neutron and synchrotron diffraction measurements of residual stress in bead-on-plate weldments

    International Nuclear Information System (INIS)

    Paradowska, A.M.; Price, J.W.; Finlayson, T.R.; Lienert, U.; Ibrahim, R.

    2010-01-01

    This paper explores the use of neutron and synchrotron diffractions for the evaluation of residual stresses in welded components. It has been shown that it is possible to achieve very good agreement between the two independent diffraction techniques. This study shows the significance of the weld start and end sites on the residual strain/stress distribution. Quantitative evaluation of the residual stress development process for multibead weldments has been presented. Some measurements were also taken before and after postweld stress relieving to establish the reduction and redistribution of the residual stress. The detailed measurements of residual stress around the weld achieved in this work significantly improve the knowledge and understanding of residual stress in welded components.

  13. The role and effect of residual stress on pore generation during anodization of aluminium thin films

    International Nuclear Information System (INIS)

    Liao, M.W.; Chung, C.K.

    2013-01-01

    Highlights: •Al films of varying residual stress were prepared by sputtering. •Variation of the residual stress in the Al films influences pore growth during anodization. •The change in average pore size with residual stress is fairly small. •Interaction of residual stress with oxide growth stress leads to change in structure. •Residual tensile stress increases the pore density of porous alumina. -- Abstract: The role and effect of residual stress on pore generation of anodized aluminium oxide (AAO) have been investigated into anodizing the various-residual-stresses aluminium films. The plane stresses were characterised by X-ray diffraction with sin 2 ψ method. The pore density roughly linearly increased with residual stress from 64.6 (−132.5 MPa) to 90.5 pores/μm 2 (135.9 MPa). However, the average pore size around 40 nm was not changed significantly except for the rougher film. The tensile residual stress lessened the compressive oxide growth stress to reduce AAO plastic deformation for higher pore density. The findings provide new foundations for realizing AAO films on silicon

  14. Verification of an optimized condition for low residual stress employed water-shower cooling during welding in austenitic stainless steel plates

    International Nuclear Information System (INIS)

    Yanagida, N.; Enomoto, K.; Anzai, H.

    2004-01-01

    To reduce tensile residual stress in a welded region, we have developed a new cooling method that uses a water-shower behind the welding torch. When this method is applied to the welding of austenitic stainless steel, the welding and cooling conditions mainly determine how much the residual stress can be reduced. To optimize these conditions, we first used a robust design method to determine the effects of the preheating temperature, the heat input quantity, and the water-shower area on the residual stress, and found that, to decrease the tensile residual stress, the preheating temperature should be high, the heat input low, and the water-shower area large. To confirm the effectiveness of these optimized conditions, the residual stresses under optimized or non-optimized conditions were measured experimentally. It was found that the residual stresses were tensile under the non-optimized conditions, but compressive under the optimized ones. These measurements agree well with the 3D-FEM analyses. It can therefore be concluded that the optimized conditions are valid and appropriate for reducing residual stress in an austenitic stainless-steel weld. (orig.)

  15. FEM Analysis and Measurement of Residual Stress by Neutron Diffraction on the Dissimilar Overlay Weld Pipe

    International Nuclear Information System (INIS)

    Kim, Kang Soo; Lee, Ho Jin; Woo, Wan Chuck; Seong, Baek Seok; Byeon, Jin Gwi; Park, Kwang Soo; Jung, In Chul

    2010-01-01

    Much research has been done to estimate the residual stress on a dissimilar metal weld. There are many methods to estimate the weld residual stress and FEM (Finite Element Method) is generally used due to the advantage of the parametric study. And the X-ray method and a Hole Drilling technique for an experimental method are also usually used. The aim of this paper is to develop the appropriate FEM model to estimate the residual stresses of the dissimilar overlay weld pipe. For this, firstly, the specimen of the dissimilar overlay weld pipe was manufactured. The SA 508 Gr3 nozzle, the SA 182 safe end and SA376 pipe were welded by the Alloy 182. And the overlay weld by the Alloy 52M was performed. The residual stress of this specimen was measured by using the Neutron Diffraction device in the HANARO (High-flux Advanced Neutron Application ReactOr) research reactor, KAERI (Korea Atomic Energy Research Institute). Secondly, FEM Model on the dissimilar overlay weld pipe was made and analyzed by the ABAQUS Code (ABAQUS, 2004). Thermal analysis and stress analysis were performed, and the residual stress was calculated. Thirdly, the results of the FEM analysis were compared with those of the experimental methods

  16. Influence of ion irradiation on internal residual stress in DLC films

    Energy Technology Data Exchange (ETDEWEB)

    Karaseov, Platon A., E-mail: platon.karaseov@rphf.spbstu.r [St. Petersburg State Polytechnic University, Polytechnicheskaya St. 29, 195251 St. Petersburg (Russian Federation); Podsvirov, Oleg A.; Karabeshkin, Konstantin V. [St. Petersburg State Polytechnic University, Polytechnicheskaya St. 29, 195251 St. Petersburg (Russian Federation); Vinogradov, Andrei Ya. [Ioffe Physicotechnical Institute RAS, Polytechnicheskaya 26, 195252 St. Petersburg (Russian Federation); Azarov, Alexander Yu. [St. Petersburg State Polytechnic University, Polytechnicheskaya St. 29, 195251 St. Petersburg (Russian Federation); Karasev, Nikita N. [State University of Information Technologies, Mechanics and Optics, Sablinskaya Str. 14, 197101 St. Petersburg (Russian Federation); Titov, Andrei I.; Smirnov, Alexander S. [St. Petersburg State Polytechnic University, Polytechnicheskaya St. 29, 195251 St. Petersburg (Russian Federation)

    2010-10-01

    The dependence of internal residual stress in thin diamond-like carbon films grown on Si substrate by PECVD technique on most important growth parameters, namely RF-power, DC bias voltage and substrate temperature, is described. Results show that compressive stress reaches the highest value of 2.7 GPa at low RF-power and DC bias. Increase of substrate temperature from 250 to 350 {sup o}C leads to nonlinear increase of stress value. Inhomogeneity of residual stress along the film surface disappears when film is deposited at temperatures above 275 {sup o}C. Post-growth film irradiation by P{sup +} and In{sup +} ions cause decrease of compressive stress followed by its inversion to tensile. For all ion energy combinations used residual stress changes linearly with normalized fluence up to 0.2 DPA with slope (8.7 {+-} 1.3) GPa/DPA.

  17. Analysis of macro and micro residual stresses in functionally graded materials by diffraction methods

    CERN Document Server

    Dantz, D; Reimers, W

    1999-01-01

    The residual stress state in microwave sintered metal-ceramic functionally graded materials (FGM) consisting of 8Y-ZrO/sub 2//Ni and 8Y-ZrO/sub 2//NiCr8020, respectively, was analysed by non- destructive diffraction methods. In $9 order to get knowledge of the complete residual stress state in the near surface region as well as in the interior of the material, complementary methods were applied. Whereas the surface was characterised by X-ray techniques using $9 conventional sources, the stresses within the bulk of the material were investigated by means of high energy synchrotron radiation. The stress state was found to obey the differences in the coefficients of thermal expansion $9 (micro-stresses) on the one hand and the inhomogeneous cooling conditions (macrostresses) on the other hand. (7 refs).

  18. Evaluation of residual stresses in welded part using hard synchrotron x-rays

    International Nuclear Information System (INIS)

    Suzuki, Kenji; Shobu, Takahisa; Shiro, Ayumi; Zhang Shuoyuan

    2013-01-01

    The spiral slit-system and DSTM (diffraction spot trace method) are under development in order to evaluate internal stresses of materials with coarse grains. The spiral slit-system was improved so that the length of the gauge volume is independent of the diffraction angle. The bending stress in the specimen with coarse grains was measured in order to confirm performance of this advanced spiral slit-system. The distribution of the measured bending stress coincided with the applied bending stress. As a result, it was proved that the combination of the advanced spiral slit-system and the DSTM is useful for the internal stress measurement of materials with coarse grains. The welded specimen of a Mg-alloy plate was prepared by melt-run with TIG welding. The residual stress map in the cross-section of the specimen was made using the DSTM. On the other hand, the residual stresses of the welded specimen were simulated by a finite element method. Although the measured residual stresses were similar to the simulated results, the residual stresses due to extrusion were measured also using the DSTM. The DSTM is an excellent technique for the stress measurement of weld parts. (author)

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

    Energy Technology Data Exchange (ETDEWEB)

    Dong, P.; Rahman, S.; Wilkowski, G. [and others

    1997-04-01

    This paper summarizes four different studies undertaken to evaluate the effects of weld residual stresses on the crack-opening behavior of a circumferential through-wall crack in the center of a girth weld. The effect of weld residual stress on the crack-opening-area and leak-rate analyses of a pipe is not well understood. There are no simple analyses to account for these effects, and, therefore, they are frequently neglected. The four studies involved the following efforts: (1) Full-field thermoplastic finite element residual stress analyses of a crack in the center of a girth weld, (2) A comparison of the crack-opening displacements from a full-field thermoplastic residual stress analysis with a crack-face pressure elastic stress analysis to determine the residual stress effects on the crack-opening displacement, (3) The effects of hydrostatic testing on the residual stresses and the resulting crack-opening displacement, and (4) The effect of residual stresses on crack-opening displacement with different normal operating stresses.

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

    International Nuclear Information System (INIS)

    Dong, P.; Rahman, S.; Wilkowski, G.

    1997-01-01

    This paper summarizes four different studies undertaken to evaluate the effects of weld residual stresses on the crack-opening behavior of a circumferential through-wall crack in the center of a girth weld. The effect of weld residual stress on the crack-opening-area and leak-rate analyses of a pipe is not well understood. There are no simple analyses to account for these effects, and, therefore, they are frequently neglected. The four studies involved the following efforts: (1) Full-field thermoplastic finite element residual stress analyses of a crack in the center of a girth weld, (2) A comparison of the crack-opening displacements from a full-field thermoplastic residual stress analysis with a crack-face pressure elastic stress analysis to determine the residual stress effects on the crack-opening displacement, (3) The effects of hydrostatic testing on the residual stresses and the resulting crack-opening displacement, and (4) The effect of residual stresses on crack-opening displacement with different normal operating stresses

  1. Residual stresses in a co-sintered SOC half-cell during post-sintering cooling

    DEFF Research Database (Denmark)

    Charlas, Benoit; Chatzichristodoulou, Christodoulos; Brodersen, Karen

    2014-01-01

    .e. the reference temperature (Tref) or the strain difference based on the curvature. This approximation gives good results for bilayers with a defined cooling temperature profile, where the curvature of the bilayer defines a unique balance between the two unknown residual stress states in the two layers......Due to the thermal expansion mismatch between the layers of a Solid Oxide Cell, residual stresses (thermal stresses) develop during the cooling after sintering. Residual stresses can induce cell curvature for asymmetric cells but more importantly they also result in more fragile cells. Depending...... on the loading conditions, the additional stress needed to break the cells can indeed be smaller due to the initial thermo-mechanical stress state. The residual stresses can for a bilayer cell be approximated by estimating the temperature at which elastic stresses start to build up during the cooling, i...

  2. Numerical simulation of transformation-induced microscopic residual stress in ferrite-martensite lamellar steel

    International Nuclear Information System (INIS)

    Mikami, Y; Inao, A; Mochizuki, M; Toyoda, M

    2009-01-01

    The effect of transformation-induced microscopic residual stress on fatigue crack propagation behavior of ferrite-martensite lamellar steel was discussed. Fatigue tests of prestrained and non-prestrained specimens were performed. Inflections and branches at ferrite-martensite boundaries were observed in the non-prestrained specimens. On the other hand, less inflections and branches were found in the prestrained specimens. The experimental results showed that the transformation induced microscopic residual stress has influence on the fatigue crack propagation behavior. To estimate the microscopic residual, a numerical simulation method for the calculation of microscopic residual stress stress induced by martensitic transformation was performed. The simulation showed that compressive residual stress was generated in martensite layer, and the result agree with the experimental result that inflections and branches were observed at ferrite-martensite boundaries.

  3. Comparison of residual stress measurement in thin films using surface micromachining method

    International Nuclear Information System (INIS)

    He, Q.; Luo, Z.X.; Chen, X.Y.

    2008-01-01

    Conductive, dielectric, semiconducting, piezoelectric and ferroelectric thin films are extensively used for MEMS/NEMS applications. One of the important parameters of thin films is residual stress. The residual stress can seriously affect the properties, performance and long-term stability of the films. Excessive compressive or tensile stress results in buckling, cracking, splintering and sticking problems. Stress measurement techniques are therefore essential for both process development and process monitoring. Many suggestions for stress measurement in thin films have been made over the past several decades. This paper is concentrated on the in situ stress measurement using surface micromachining techniques to determine the residual stress. The authors review and compare several types of stress measurement methods including buckling technique, rotating technique, micro strain gauge and long-short beam strain sensor

  4. Specific features of the determination of residual stresses in materials by diffraction techniques

    Science.gov (United States)

    Gorkunov, E. S.; Zadvorkin, S. M.; Goruleva, L. S.

    2017-12-01

    Residual stresses arising in separate machine parts and structural components during production and use to a large extent govern their lifetime. In this connection, the development and improvement of nondestructive methods for the determination of residual stresses is an important task for nondestructive testing. Standards regulate only the determination of macroscopic stresses, and in practice these stresses are most often determined with the application of the sin2ψ method. This paper, using quenched structural steels as an example, compares the results of residual stress determination by the sin2ψ method with those obtained by the method based on the analysis of the diffraction line profile as dependent on the value of the irradiated volume. It is demonstrated that, as the irradiated volume decreases, the value of residual stresses determined by the sin2ψ method may vary considerably, up to the change of the sign. For a more complete characteristic of residual stresses it is proposed to use, besides the determination of macrostresses by the shift of the diffraction lines, the value of microscopic stresses calculated from the line profile analysis.

  5. Measurement of residual stress in a sphere by x-ray under the consideration of its penetration depth

    International Nuclear Information System (INIS)

    Doi, Osamu; Ukai, Takayoshi

    1981-01-01

    It was pointed out in the case of a plate that when stress gradient is large, the use of the X-ray with large penetration depth caused large measurement error. In this paper, the theoretical equations for measuring the residual stress in a sphere with X-ray, taking penetration depth into account, are proposed, and the example of application is shown. As the method of measuring the residual stress in a hollow sphere with X-ray, only the method of combining external surface removal and external surface irradiation is practically in use. It was assumed that a sphere is isotropic, and that the residual stress is a function of the radius only. First, the theory of measuring the residual stress in a sphere with X-ray taking penetration depth into account is explained, and the equations for calculating the residual stresses in tangential and radial directions are derived. As the example of applying this theory, the distribution of the residual stress in a steel ball for a ball bearing was measured with Cr characteristic X-ray. The ball of 30 mm diameter was made of high-carbon chromium bearing steel, grade 2, (JIS SUJ2) and quenched and tempered. The removal of the thin layer was made by chemical etching and electrolysis. The measured values and the calculated values are shown. (Kako, I.)

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

    Science.gov (United States)

    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.

  7. The significance of residual stresses in relation to the integrity of LWR pressure vessels

    International Nuclear Information System (INIS)

    Lidbury, D.P.G.

    1984-01-01

    The level and distribution of residual stresses in heavy section weldments and the factors affecting their relaxation with post-weld heat treatment (PWHT) are discussed; residual stresses are also considered in relation to the deposition of austenitic strip cladding and repair welding. A brief survey is made of currently available methods of measuring surface and sub-surface residual stresses in heavy section weldments; the effects of compressive residual stresses on the detection and sizing of planar defects are similarly considered. Available fracture mechanics methodologies with the capability of evaluation defect significance in the presence of residual and other secondary stresses are reviewed in some detail. On-going experimental investigations of the effects of residual stresses on structural integrity are also described. Following a general discussion, the desirability of internationally agreed Codes and Methods for assessing defects in the presence of residual and other self-limiting stresses is pointed out. It is argued that before such agreement could be achieved, however, further work is necessary, and a number of recommendations are given. (author)

  8. Process induced residual stresses and distortions in pultrusion

    DEFF Research Database (Denmark)

    Baran, Ismet; Tutum, Cem Celal; Nielsen, Michael Wenani

    2013-01-01

    In the present study, a coupled 3D transient Eulerian thermo-chemical analysis together with a 2D plane strain Lagrangian mechanical analysis of the pultrusion process, which has not been considered until now, is carried out. The development of the process induced residual stresses and strains...... together with the distortions are predicted during the pultrusion in which the cure hardening instantaneous linear elastic (CHILE) approach is implemented. At the end of the process, tension stresses prevail for the inner region of the composite since the curing rate is higher here as compared to the outer...... regions where compression stresses are obtained. The separation between the heating die and the part due to shrinkage is also investigated using a mechanical contact formulation at the die-part interface. The proposed approach is found to be efficient and fast for the calculation of the residual stresses...

  9. Surface residual stress evaluation in double-electrode butt welded steel plates

    International Nuclear Information System (INIS)

    Estefen, S.F.; Gurova, T.; Castello, X.; Leontiev, A.

    2010-01-01

    Surface residual stress evaluation for double-electrode welding was studied. The stresses were monitored after each operational step: positioning, implementing of constraints, welding and constraints removal. The measurements were performed at the deposited metal, heat affected zone, base metal close to the weld joint and along the plate using the X-ray diffraction method. It was observed differences in the stress evaluations for double-electrode welding which resulted in lower bending distortions and higher values of surface residual stresses, compared with single-electrode welding. This behavior is associated with the stress distribution just after the welding processes in both heat affected zone and base metal close to the fillet for double-electrode welding. The main results from the laboratorial tests indicated lower values of the bending distortions for double-electrode welding compared with the single-electrode. In relation to the residual stress, the double-electrode welding generated, in general, higher stress values in both longitudinal and transversal directions.

  10. Study of residual stresses in welded joints of dual phase HSLA steel used in automotive industry

    International Nuclear Information System (INIS)

    Barbato, D.S.; Fonseca, M.P. Cindra; Marques Junior, A.S.; Chuvas, T.C.; Pardal, J.M.

    2010-01-01

    One way of weight reduction in automotive vehicles is through the use of high strength and low alloy (HSLA) steels, which enables the use of small thickness plates. Whereas the appearance of residual stresses is intrinsic to the welding process, this study evaluates the residual stresses generated in welded joints obtained by TIG and LASER welding processes and comparing them. Residual stresses were measured by X-rays diffraction technique, using a portable device with Crκα radiation applying the double exposure method. It also evaluates the influence of shot peening treatment applied after welding, in the bend tests conducted for both welding conditions and TIG welded joints showed higher stability of compressive stresses after welding. The metallographic analysis by optical microscopy complemented the welded joints characterization. (author)

  11. Experimental Analysis of Residual Stresses in Samples of Austenitic Stainless Steel Welded on Martensitic Stainless Steel Used for Kaplan Blades Repairs

    Directory of Open Access Journals (Sweden)

    Vasile Cojocaru

    2011-01-01

    Full Text Available Residual stresses occur in materials as a result of mechanical processes: welding, machining, grinding etc. If residual stresses reach high values they can accelerate the occurrence of cracks and erosion of material. An experimental research was made in order to study the occurrence of residual stresses in the repaired areas of hydraulic turbine components damaged by cavitation erosion. An austenitic stainless steel was welded in various layer thicknesses on a martensitic stainless steel base. The residual stresses were determined using the hole drilling strain gage method.

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

    Science.gov (United States)

    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

  13. Residual stresses in non-symmetrical carbon-epoxy laminates

    NARCIS (Netherlands)

    Wijskamp, Sebastiaan; Akkerman, Remko; Lamers, E.A.D.; Martin, M.J.; Hahn, H.T.

    2003-01-01

    The curvature of unsymmetrical [0/90] laminates moulded from AS4/8552 uni-directional tape has been measured. A linear thermoelastic approach has been applied to predict the related residual stress state before demoulding, giving an estimate of the stress induced by polymerisation strain. The

  14. Residual stresses in a cast iron automotive brake disc rotor

    International Nuclear Information System (INIS)

    Ripley, Maurice I.; Kirstein, Oliver

    2006-01-01

    Runout, and consequent juddering and pulsation through the brake pedal, is a multi-million dollar per year warranty problem for car manufacturers. There is some suspicion that the runout can be caused by relaxation of residual casting stresses when the disc is overheated during severe-braking episodes. We report here neutron-diffraction measurements of the levels and distribution of residual strains in a used cast iron brake disc rotor. The difficulties of measuring stresses in grey cast iron are outlined and three-dimensional residual-strain distributions are presented and their possible effects discussed

  15. Analysis of residual stress in subsurface layers after precision hard machining of forging tools

    Directory of Open Access Journals (Sweden)

    Czan Andrej

    2018-01-01

    Full Text Available This paper is focused on analysis of residual stress of functional surfaces and subsurface layers created by precision technologies of hard machining for progressive constructional materials of forging tools. Methods of experiments are oriented on monitoring of residual stress in surface which is created by hard turning (roughing and finishing operations. Subsequently these surfaces were etched in thin layers by electro-chemical polishing. The residual stress was monitored in each etched layer. The measuring was executed by portable X-ray diffractometer for detection of residual stress and structural phases. The results significantly indicate rise and distribution of residual stress in surface and subsurface layers and their impact on functional properties of surface integrity.

  16. Microstructure and temperature dependence of intergranular strains on diffractometric macroscopic residual stress analysis

    Energy Technology Data Exchange (ETDEWEB)

    Wagner, J.N., E-mail: Julia.Wagner@kit.edu [KNMF, Karlsruhe Institute of Technology, Hermann-von-Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen (Germany); Hofmann, M. [Forschungs-Neutronenquelle Heinz Maier-Leibnitz (FRM II), TU München, Lichtenbergstr. 1, 85747 Garching (Germany); Wimpory, R. [Helmholtz-Zentrum Berlin für Materialien und Energie, D-14109 Berlin Wannsee (Germany); Krempaszky, C. [Christian-Doppler-Labor für Werkstoffmechanik von Hochleistungslegierungen, TU München, Boltzmannstr. 15, 85747 Garching (Germany); Lehrstuhl für Werkstoffkunde und Werkstoffmechanik, TU München, Boltzmannstr. 15, 85747 Garching (Germany); Stockinger, M. [Böhler Schmiedetechnik GmbH and Co KG, Mariazeller Straße 25, 8605 Kapfenberg (Austria)

    2014-11-17

    Knowledge of the macroscopic residual stresses in components of complex high performance alloys is crucial when it comes to considering the safety and manufacturing aspects of components. Diffraction experiments are one of the key methods for studying residual stresses. However a component of the residual strain determined by diffraction experiments, known as microstrain or intergranular residual strain, occurs over the length scale of the grains and thus plays only a minor role for the life time of such components. For the reliable determination of macroscopic strains (with the minimum influence of these intergranular residual strains), the ISO standard recommends the use of particular Bragg reflections. Here we compare the build-up of intergranular strain of two different precipitation hardened IN 718 (INCONEL 718) samples, with identical chemical composition. Since intergranular strains are also affected by temperature, results from room temperature measurement are compared to results at T=550 °C. It turned out that microstructural parameters, such as grain size or type of precipitates, have a larger effect on the intergranular strain evolution than the influence of temperature at the measurement temperature of T=550 °C. The results also show that the choice of Bragg reflections for the diffractometric residual stress analysis is dependent not only on its chemical composition, but also on the microstructure of the sample. In addition diffraction elastic constants (DECs) for all measured Bragg reflections are given.

  17. Assessment of residual stress of 7050-T7452 aluminum alloy forging using the contour method

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, Zheng [College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016 (China); Yang, Yinfei, E-mail: yyfgoat@nuaa.edu.cn [College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016 (China); Li, Liang [College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016 (China); Chen, Bo; Tian, Hui [Xi’an Aircraft Industrial (Group) Co. Ltd., Xi’an 710000 (China)

    2015-09-17

    The cold-compression stress relief process has been used to reduce the quench-induced stresses in high-strength aerospace aluminum alloy forgings. However, this method does not completely relieve the stress. Longitudinal residual stresses in 7050-T7452 aluminum alloy forging were measured with contour method. The measuring procedure of the contour method including specimen cutting under clamps with a wire electrical discharge machine, contour measurement of the cut surface with a laser scanner, careful data processing and elastic finite element analysis was introduced in detail. In addition, multiple cuts were used to map cross sectional stress at different cut surfaces. Finally, the longitudinal residual stress throughout the cut plane was mapped, and through thickness longitudinal stress profiles were also analyzed. Investigated results suggest that spatial variation of stress distribution can be attributed to the non-uniform plastic deformation of the cold-compression stress relief process. The overall reduction of peak stress magnitudes is approximately 43–79%.

  18. Assessment of residual stress of 7050-T7452 aluminum alloy forging using the contour method

    International Nuclear Information System (INIS)

    Zhang, Zheng; Yang, Yinfei; Li, Liang; Chen, Bo; Tian, Hui

    2015-01-01

    The cold-compression stress relief process has been used to reduce the quench-induced stresses in high-strength aerospace aluminum alloy forgings. However, this method does not completely relieve the stress. Longitudinal residual stresses in 7050-T7452 aluminum alloy forging were measured with contour method. The measuring procedure of the contour method including specimen cutting under clamps with a wire electrical discharge machine, contour measurement of the cut surface with a laser scanner, careful data processing and elastic finite element analysis was introduced in detail. In addition, multiple cuts were used to map cross sectional stress at different cut surfaces. Finally, the longitudinal residual stress throughout the cut plane was mapped, and through thickness longitudinal stress profiles were also analyzed. Investigated results suggest that spatial variation of stress distribution can be attributed to the non-uniform plastic deformation of the cold-compression stress relief process. The overall reduction of peak stress magnitudes is approximately 43–79%

  19. Distortion and residual stresses in structures reinforced with titanium straps for improved damage tolerance

    International Nuclear Information System (INIS)

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

    2008-01-01

    Distortion and residual stresses induced during the manufacturing process of bonded crack retarders have been investigated. Titanium alloy straps were adhesively bonded to an aluminium alloy SENT specimen to promote fatigue crack growth retardation. The effect of three different strap dimensions was investigated. The spring-back of a component when released from the autoclave and the residual stresses are important factors to take into account when designing a selective reinforcement, as this may alter the local aerodynamic characteristics and reduce the crack bridging effect of the strap. The principal problem with residual stresses is that the tensile nature of the residual stresses in the primary aluminium structure has a negative impact on the crack initiation and crack propagation behaviour in the aluminium. The residual stresses were measured with neutron diffraction and the distortion of the specimens was measured with a contour measurement machine. The bonding process was simulated with a three-dimensional FE model. The residual stresses were found to be tensile close to the strap and slightly compressive on the un-bonded side. Both the distortion and the residual stresses increased with the thickness and the width of the strap. Very good agreement between the measured stresses and the measured distortion and the FE simulation was found

  20. X-ray measurement of residual stress in metals at Chalk River Nuclear Laboratories

    International Nuclear Information System (INIS)

    Winegar, J.E.

    1980-06-01

    X-ray diffraction is used at CRNL to measure residual stress in metals. This report summarizes the basic principles of stress measurement, and reviews factors affecting accuracy of measurement. The technique and equipment described were developed at CRNL to give reliable measurements. Accuracy of measurement is achieved by using fixed-count step-scanning and by computer analysis of intensity data using a cubic spline curve smoothing routine. Specific reference is made to the measurement of residual stress in Inconel-600 and Incoloy-800 boiler tubing. Because it measures stress in thin surface layers, the X-ray method can also be used to measure the depth profile of stresses. As there are no standardized procedures for measuring residual stress, this report will be useful both to those unfamiliar with the measurement of residual stress and to those already making such measurements in other laboratories. (auth)

  1. Residual stress improvement in multi-layer welded plates using water-shower cooling during welding process

    International Nuclear Information System (INIS)

    Yanagida, Nobuyoshi; Koide, Hiroo

    2006-01-01

    To reduce tensile residual stress in a welded region, we developed a new welding method that applies a water-shower behind the welding torch. When this method is applied to welding of austenitic stainless steel plates, cooling conditions mainly determine how much the residual stress can be reduced. To determine the conditions, we first used FEM to evaluate the effects of interpass temperature on the residual stress. And we found effective conditions for reducing tensile residual stress. To verify the validity of the conditions, specimens welded with or without water shower cooling were manufactured. Residual stresses of the specimens were experimentally measured. It was found that tensile residual stresses were generated on the surface of the welds and those were reduced in the case that the water-shower was applied. These measurement results agree well with the FEM analyses. It can therefore be concluded that the water-shower cooling during welding is appropriate for reducing tensile residual stress in austenitic stainless steel welding. (author)

  2. Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

    Science.gov (United States)

    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.

  3. On the role of the residual stress state in product manufacturing

    NARCIS (Netherlands)

    Zijlstra, G.; Groen, M.; Post, J.; Ocelik, V.; de Hosson, J.Th.M.

    2016-01-01

    This paper concentrates on the effect of the residual stress state during product manufacturing of AISI 420 steel on the final shape of the product. The work includes Finite Element (FE) calculations of the distribution of the residual stresses after metal forming and a heat treatment. The evolution

  4. Role of symmetry-breaking induced by Er × B shear flows on developing residual stresses and intrinsic rotation in the TEXTOR tokamak

    International Nuclear Information System (INIS)

    Xu, Y.; Shesterikov, I.; Berte, M.; Dumortier, P.; Van Schoor, M.; Vergote, M.; Hidalgo, C.; Krämer-Flecken, A.; Koslowski, R.

    2013-01-01

    Direct measurements of residual stress (force) have been executed at the edge of the TEXTOR tokamak using multitip Langmuir and Mach probes, together with counter-current NBI torque to balance the existing toroidal rotation. Substantial residual stress and force have been observed at the plasma boundary, confirming the existence of a finite residual stress as possible mechanisms to drive the intrinsic toroidal rotation. In low-density discharges, the residual stress displays a quasi-linear dependence on the local pressure gradient, consistent with theoretical predictions. At high-density shots the residual stress and torque are strongly suppressed. The results show close correlation between the residual stress and the E r × B flow shear rate, suggesting a minimum threshold of the E × B flow shear required for the k ∥ symmetry breaking. These findings provide the first experimental evidence of the role of E r × B sheared flows in the development of residual stresses and intrinsic rotation. (letter)

  5. Two-step method to evaluate equibiaxial residual stress of metal surface based on micro-indentation tests

    International Nuclear Information System (INIS)

    Nishikawa, Masaaki; Soyama, Hitoshi

    2011-01-01

    Highlights: → The sensitivity to residual stress was improved by selecting the depth parameter. → Residual stress could be obtained while determining the effect of unknown parameters. → The estimated residual stress agreed well with those of X-ray diffraction. -- Abstract: The present study proposed a method to evaluate the equibiaxial compressive residual stress of a metal surface by means of a depth-sensing indentation method using a spherical indenter. Inverse analysis using the elastic-plastic finite-element model for an indentation test was established to evaluate residual stress from the indentation load-depth curve. The proposed inverse analysis utilizes two indentation test results for a reference specimen whose residual stress is already known and for a target specimen whose residual stress is unknown, in order to exclude the effect of other unknown mechanical properties, such as Young's modulus and yield stress. Residual stress estimated by using the indentation method is almost identical to that measured by X-ray diffraction for indentation loads of 0.49-0.98 N. Therefore, it can be concluded that the proposed method can effectively evaluate residual stress on metal surface.

  6. An Evaluation on the Residual Stresses Induced by EFR Welding of CEDM Nozzle

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Sang Ho; Park, Gi Yeol; Kim, Tae Ryong [KEPCO International Nuclear Graduate School, Ulsan (Korea, Republic of)

    2015-10-15

    In this paper, carried out the welding analysis to use the SYSWELD as welding interpretation code based on the reactor upper head nozzle. In this paper, evaluated the residual stress in CEDM nozzle by EFR through the SYSWELD which is the welding interpretation code. The conclusion are same as below. 1) When comparing with Hoop Stress and Axial Stress by J-Groove and EFR, after welding residual stress by EFR is lower than after J-Groove. 2) After EFR, it was confirmed that the tensile stress is reduced after increasing over the point3. The PWSCC of Dissimilar Metal Zone of reactor can degrade the integrity of the main device in nuclear power plant, and according to the power plant stopped for inspection, it can cause an enormous amount of lost sales when the crack is occurred. Various methods have been developed to reduce residual stress to prevent the PWSCC like Weld Overlay (WOL), Mechanical Stress Improvement Process (Msp), Laser Peening, Inlay Weld, etc. Among them, Wol is the most commonly used welding method in nuclear power plant. When performing a Wol, structure rigidity will be increase, and residual stress of welding zone will be changed into compressive stress from the tensile stress. This has the advantage that improved resistance to PWSCC. The most commonly used material in nuclear power plant is Inconel 600. Inconel 600 consist of a Ni-Cr-Fe and it has 14-17% of Cr content, 10% of Fe content and susceptible to PWSCC. The more Cr content is more stronger against PWSCC. Inconel 690 which has 2 times more Cr content than Inconel 600 has very strong resistance to PWSCC than Inconel 600. Embedded Flaw Repair (EFR) has been developed in Westinghouse by 1994. The welding metal with high corrosion resistance is embedded on the surface of component, and could protect cracking part from the PWSCC. It is permanent repair method that isolates the flaw from the environment, eliminating further crack propagation due to PWSCC. EFR method is that at least three layers

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

    Science.gov (United States)

    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. Residual stresses relaxation in surface-hardened half-space under creep conditions

    Directory of Open Access Journals (Sweden)

    Vladimir P. Radchenko

    2015-09-01

    Full Text Available We developed the method for solving the problem of residual stresses relaxation in surface-hardened layer of half-space under creep conditions. At the first stage we made the reconstruction of stress-strain state in half-space after plastic surface hardening procedure based on partial information about distribution for one residual stress tensor component experimentally detected. At the second stage using a numerical method we solve the problem of relaxation of self-balanced residual stresses under creep conditions. To solve this problem we introduce the following Cartesian system: x0y plane is aligned with hardened surface of half-space and 0z axis is directed to the depth of hardened layer. We also introduce the hypotheses of plane sections parallel to x0z and y0z planes. Detailed analysis of the problem has been done. Comparison of the calculated data with the corresponding test data was made for plane specimens (rectangular parallelepipeds made of EP742 alloy during T=650°C after the ultrasonic hardening with four hardening modes. We use half-space to model these specimens because penetration's depth of residual stresses is less than specimen general size in two digit exponent. There is enough correspondence of experimental and calculated data. It is shown that there is a decay (in modulus of pressing residual stresses under creep in 1.4–1.6 times.

  9. Stress-Softening and Residual Strain Effects in Suture Materials

    Directory of Open Access Journals (Sweden)

    Alex Elías-Zúñiga

    2013-01-01

    Full Text Available This work focuses on the experimental characterization of suture material samples of MonoPlus, Monosyn, polyglycolic acid, polydioxanone 2–0, polydioxanone 4–0, poly(glycolide-co-epsilon-caprolactone, nylon, and polypropylene when subjected to cyclic loading and unloading conditions. It is found that all tested suture materials exhibit stress-softening and residual strain effects related to the microstructural material damage upon deformation from the natural, undistorted state of the virgin suture material. To predict experimental observations, a new constitutive material model that takes into account stress-softening and residual strain effects is developed. The basis of this model is the inclusion of a phenomenological nonmonotonous softening function that depends on the strain intensity between loading and unloading cycles. The theory is illustrated by modifying the non-Gaussian average-stretch, full-network model to capture stress-softening and residual strains by using pseudoelasticity concepts. It is shown that results obtained from theoretical simulations compare well with suture material experimental data.

  10. The effects of location, thermal stress, and residual stress on corner cracks in nozzles with cladding

    International Nuclear Information System (INIS)

    Besuner, P.M.; Cohen, L.M.; McLean, J.L.

    1977-01-01

    The stress intensity factors (Ksub(I)) for corner cracks in a boiling water reactor feedwater nozzle with stainless steel cladding are obtained for loading by internal pressure, and a fluid quench in the nozzle. Conditions with and without residual stress in the component are considered. The residual stress is simulated by means of a reference temperature change. The stress distribution for the uncracked structure is obtained from a three-dimensional finite element model. A three-dimensional influence function (IF) method, in conjunction with the boundary-integral equation method for structural analysis, is employed to compute Ksub(I) values from the uncracked structure's stress distribution. For each type of loading Ksub(I) values are given for cracks at 15 nozzle locations and for six crack depths. Reasonable agreement is noted between calculated and previously published pressure-induced Ksub(I) values. Comparisons are made to determine the effect on Ksub(I) of crack location, thermal stress, and residual stress as compared to pressure stress. For the thermal transient it is shown that Ksub(I) for small crack depths is maximized early in the transient while Ksub(I) for large cracks is maximized later, under steady state conditions. Ksub(I) computations should, therefore, be made for several transient time points and the maximum Ksub(I) for a given crack depth should be used for design analysis. It is concluded that the effects on Ksub(I) of location, thermal stresses, and residual stresses are significant and generally too complex to evalute without advanced numerical procedures. The utilized combination of finite element analysis of the uncracked structure and three-dimensional influence function analysis of the cracked structure is demonstrated

  11. Analytical description of fatigue crack propagation regularities taking into account residual welding stresses

    International Nuclear Information System (INIS)

    Trufyakov, V.I.; Knysh, V.V.; Mikheev, P.P.; Kuz'menko, A.Z.

    1983-01-01

    The procedure, accounting the effect of residual stresses on crack resistance of welded constructions under cyclic loads, is described. The procedure is based on the Paris equation modified by the introduction of the coefficient of residual stress intensity through the functional dependence. The dependence is determined for cases of residual stresses of tension and compression. The experimental data for the 15KhSND steel are presented

  12. Development of residual thermal stress-relieving structure of CFC monoblock target for JT-60SA divertor

    Energy Technology Data Exchange (ETDEWEB)

    Tsuru, Daigo, E-mail: tsuru.daigo@jaea.go.jp; Sakurai, Shinji; Nakamura, Shigetoshi; Ozaki, Hidetsugu; Seki, Yohji; Yokoyama, Kenji; Suzuki, Satoshi

    2015-10-15

    Highlights: • We carried out numerical simulations on residual thermal stress of targets for the JT-60SA divertor. • We developed three measures to reduce residual thermal stress. • We proposed two structures of CFC monoblock target for the JT-60SA divertor. • We confirmed the effectiveness of the structure by infrared thermography inspection and high heat flux test. - Abstract: Carbon fibre-reinforced carbon composite (CFC) monoblock target for JT-60SA divertor is under development towards the mass-production. CFC monoblocks, WCu interlayers and a CuCrZr cooling tube at the centre of the monoblocks were bonded by vacuum brazing in a high temperature, to a target. If residual thermal stress due to difference of thermal expansions between CFC and CuCrZr exceeds the maximum allowable stress of the CFC after the bonding, cracks are generated in the CFC monoblock and heat removal capacity of the target degrades. In this paper, new structures of the targets were proposed, to reduce residual thermal stress and to mitigate the degradation of heat removal capacity of the targets. Some measures, including slitting of the CFC monoblock aside of the cooling tube, replacement of the interlayer material and shifting the position of the cooling tube, were implemented. The effectiveness of the measures was evaluated by numerical simulations. Target mock-ups with the proposed structures were manufactured. Infrared thermography inspection and high heat flux test were carried out on the mock-ups in order to evaluate the heat removal capacity.

  13. Assessment of possibility of primary water stress corrosion cracking occurrence based on residual stress analysis in pressurizer safety nozzle of nuclear power plant

    International Nuclear Information System (INIS)

    Lee, Kyoung Soo; Kim, W.; Lee, Jeong Geun

    2012-01-01

    Primary water stress corrosion cracking (PWSCC) is a major safety concern in the nuclear power industry worldwide. PWSCC is known to initiate only in the condition in which sufficiently high tensile stress is applied to alloy 600 tube material or alloy 82/182 weld material in pressurized water reactor operating environments. However, it is still uncertain how much tensile stress is required to generate PWSCC or what causes such high tensile stress. This study was performed to predict the magnitude of weld residual stress and operating stress and compare it with previous experimental results for PWSCC initiation. For the study, a pressurizer safety nozzle was selected because it is reported to be vulnerable to PWSCC in overseas plants. The assessment was conducted by numerical analysis. Before performing stress analysis for plant conditions, a preliminary mock-up analysis was done. The result of the preliminary analysis was validated by residual stress measurement in the mockup. After verification of the analysis methodology, an analysis under plant conditions was conducted. The analysis results show that the stress level is not high enough to initiate PWSCC. If a plant is properly welded and operated, PWSCC is not likely to occur in the pressurizer safety nozzle.

  14. The effect of filler metal thickness on residual stress and creep for stainless-steel plate-fin structure

    Energy Technology Data Exchange (ETDEWEB)

    Jiang Wenchun [School of Mechanical and Power Engineering, Nanjing University of Technology, Nanjing 210009 (China)], E-mail: jiangwenchun@126.com; Gong Jianming; Chen Hu; Tu, S.T. [School of Mechanical and Power Engineering, Nanjing University of Technology, Nanjing 210009 (China)

    2008-08-15

    Stainless-steel plate-fin heat exchanger (PFHE) has been used as a high-temperature recuperator in microturbine for its excellent qualities in compact structure, high-temperature and pressure resistance. Plate-fin structure, as the core of PFHE, is fabricated by vacuum brazing. The main component fins and the parting sheets are joined by fusion of a brazing alloy cladded to the surface of parting sheets. Owing to the material mismatching between the filler metal and the base metal, residual stresses can arise and decrease the structure strength greatly. The recuperator serves at high temperature and the creep would happen. The thickness of the filler metal plays an important role in the joint strength. Hence this paper presented a finite element (FE) analysis of the brazed residual stresses and creep for a counterflow stainless-steel plate-fin structure. The effect of the filler metal thickness on residual stress and creep was investigated, which provides a reference for strength design.

  15. Standard practice for estimating the approximate residual circumferential stress in straight thin-walled tubing

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2007-01-01

    1.1 A qualitative estimate of the residual circumferential stress in thin-walled tubing may be calculated from the change in outside diameter that occurs upon splitting a length of the tubing. This practice assumes a linear stress distribution through the tube wall thickness and will not provide an estimate of local stress distributions such as surface stresses. (Very high local residual stress gradients are common at the surface of metal tubing due to cold drawing, peening, grinding, etc.) The Hatfield and Thirkell formula, as later modified by Sachs and Espey, provides a simple method for calculating the approximate circumferential stress from the change in diameter of straight, thin-walled, metal tubing. 1.2 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

  16. Standard test method for determining residual stresses by the hole-drilling strain-gage method

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2008-01-01

    1.1 Residual Stress Determination: 1.1.1 This test method specifies a hole-drilling procedure for determining residual stress profiles near the surface of an isotropic linearly elastic material. The test method is applicable to residual stress profile determinations where in-plane stress gradients are small. The stresses may remain approximately constant with depth (“uniform” stresses) or they may vary significantly with depth (“non-uniform” stresses). The measured workpiece may be “thin” with thickness much less than the diameter of the drilled hole or “thick” with thickness much greater than the diameter of the drilled hole. Only uniform stress measurements are specified for thin workpieces, while both uniform and non-uniform stress measurements are specified for thick workpieces. 1.2 Stress Measurement Range: 1.2.1 The hole-drilling method can identify in-plane residual stresses near the measured surface of the workpiece material. The method gives localized measurements that indicate the...

  17. Residual Stress Analysis for Engineering Applications by Means of Neutron Diffraction

    International Nuclear Information System (INIS)

    Gndupel-Herold, Thomas; Brand, Paul C.; Prask, Henry J.

    1999-01-01

    The economic and scientific importance of neutron diffraction residual stress analysis has led to an increasing number of suitable instruments worldwide. Recently, a dedicated state-of-the-art diffractometer has been installed at the National Institute of Standards and Technology reactor. It has been used for a variety of measurements on basic and engineering stress problems. Among the most prominent examples that have been investigated are residual stresses in rails, weldments, and plasma-sprayed coatings

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

    Science.gov (United States)

    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.

  19. A neutron diffraction study of residual stress and plastic strain in welded beryllium rings

    Energy Technology Data Exchange (ETDEWEB)

    Brown, D.W.; Varma, R.; Bourke, M.A.M.; Holden, T.M. [Los Alamos National Lab., Los Alamos, NM (United States); Ely, T.; Spooner, S. [Oak Ridge National Lab., Oak Ridge, TN (United States)

    2002-07-01

    We present a study of residual stresses associated with the welding of beryllium rings. Using novel analysis techniques, information about residual stresses and plastic deformation of the base metal were obtained. In the post-welded state, the rings have a strong tensile circumferential residual stress and show evidence of significant plastic deformation. (orig.)

  20. Non-destructive measurement of residual stresses in U-0.8 wt.% Ti by neutron diffraction

    International Nuclear Information System (INIS)

    Salinas-Rodriguez, A.; Root, J.H.; Holden, T.M.; Macewen, S.R.; Ludtka, G.M.

    1990-01-01

    The macroscopic residual stress distribution in γ-quenched and stress levelled U-0.8wt% Ti alloy tubes was studied using neutron diffraction techniques. Residual strains were evaluated from the difference in d-spacings measured in the tubes and in small reference samples machined from each tube. Residual stresses were calculated with the isotropic bulk value of the elastic constraints for polycrystalline α-U. Quenching from the γ field resulted in a nearly equi-biaxial stress state at every point across the wall thickness of the tube. The magnitude of the radial stress was very small compared with that of the axial and hoop stresses which were compressive at the surfaces and tensile in the interior. Stress levelling relieved almost completely the hoop residual stress without affecting the radial stress. The axial residual stress becomes tensile through the wall thickness and remains constant at about 20% of its magnitude in the as-quenched condition

  1. A study on residual stress mitigation of the HDPE pipe for various annealing conditions

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Jong Sung [Sunchon National University, Sunchon (Korea, Republic of); Yoo, Jeong Ho [Korea Laboratory Engineering System, Daejeon (Korea, Republic of); Oh, Young Jin [KEPCO E and C, Sungnam (Korea, Republic of)

    2015-03-15

    This paper presents effects of the annealing condition variables such as temperature and time on the residual stress mitigation. The effects were investigated by using the various measurement methods such as hole-drilling method and slitting method. As a result of the investigation, the residual stress mitigation magnitude increases with increasing the annealing time and temperature. Based on the investigation results, the quantitative correlations between the annealing variables and the residual stress mitigation were derived. Finally, the effect of long-term operation under the normal operating temperature conditions on the residual stress mitigation was investigated by referring to the derived equations and performing some additional tests, and it is identified that the residual stresses are not significantly relaxed over the design lifetime of the safety class III buried HDPE pipes.

  2. ELASTIC-PLASTIC AND RESIDUAL STRESS ANALYSIS OF AN ALUMINUM DISC UNDER INTERNAL PRESSURES

    Directory of Open Access Journals (Sweden)

    Numan Behlül BEKTAŞ

    2004-02-01

    Full Text Available This paper deals with elastic-plastic stress analysis of a thin aluminum disc under internal pressures. An analytical solution is performed for satisfying elastic-plastic stress-strain relations and boundary conditions for small plastic deformations. The Von-Mises Criterion is used as a yield criterion, and elastic perfectly plastic material is assumed. Elastic-plastic and residual stress distributions are obtained from inner radius to outer radius, and they are presented in tables and figures. All radial stress components, ?r, are compressive, and they are highest at the inner radius. All tangential stress components, ??, are tensile, and they are highest where the plastic deformation begins. Magnitude of the tangential residual stresses is higher than those the radial residual stresses.

  3. Joining U.S. NRC international round robin for weld residual stress analysis. Stress analysis and validation in PWSCC mitigation program

    International Nuclear Information System (INIS)

    Maekawa, Akira; Serizawa, Hisashi; Murakawa, Hidekazu

    2012-01-01

    It is necessary to establish properly reliable weld residual stress analysis methods for accurate crack initiation and growth assessment of primary water stress corrosion cracking (PWSCC), which may occur in nickel-based dissimilar metal welds in pressurized water reactors. The U.S. Nuclear Regulatory Commission conducted an international round robin for weld residual stress analysis to improve stress analysis methods and to examine the uncertainties involved in the calculated stress values. In this paper, the results from the authors' participation in the round robin were reported. In the round robin, the weld residual stress in a nickel-based dissimilar metal weld of a pressurizer surge nozzle mock-up was computed under various analysis conditions. Based on these residual stress analysis results, a welding simulation code currently being developed that uses the iterative substructure method was validated and affecting factors on the analysis results were identified. (author)

  4. Influence of repair length on residual stress in the repair weld of a clad plate

    International Nuclear Information System (INIS)

    Jiang Wenchun; Xu, X.P.; Gong, J.M.; Tu, S.T.

    2012-01-01

    Highlights: ► Residual stress in the repair weld of a stainless steel clad plate is investigated. ► The effect of repair length on residual stress has been studied. ► Large tensile residual stress is generated in the repair weld and heat affected zone. ► With the increase of repair length, transverse stress is decreased. ► Repair length has little effect on longitudinal stress. - Abstract: A 3-D sequential coupling finite element simulation is performed to investigate the temperature field and residual stress in the repair weld of a stainless steel clad plate. The effect of repair length on residual stress has been studied, aiming to provide a reference for repairing the cracked clad plate. The results show that large tensile residual stresses are generated in the repair weld and heat affected zone (HAZ), and then decrease gradually away from the weld and HAZ. The residual stresses through thickness in the clad layer are relative uniform, while they are non-uniform in the base metal. A discontinuous stress distribution is generated across the interface between weld metal and base metal. The repair length has a great effect on transverse stress. With the increase of repair length, the transverse stress is decreased. When the repair length is increased to 14 cm, the peak of transverse stress has been decreased below yield strength, and the transverse stress in the weld and HAZ has also been greatly decreased. But the repair length has little effect on longitudinal stress.

  5. Stability of machining induced residual stresses in Inconel 718 under quasi-static loading at room temperature

    International Nuclear Information System (INIS)

    Madariaga, A.; Esnaola, J.A.; Arrazola, P.J.; Ruiz-Hervias, J.; Muñoz, P.; Ostolaza, K.

    2015-01-01

    Tensile residual stresses are very often generated on the surface when machining nickel alloys. In order to determine their influence on the final mechanical behaviour of the component residual stress stability should be considered. In the present work the evolution of surface residual stresses induced by machining in Inconel 718 under static loading at room temperature was studied experimentally and numerically. An Inconel 718 disc was face turned employing industrial working conditions and specimens for tensile tests were extracted from the disc. Surface residual stresses were measured by X-ray diffraction for initial state and after applying different loads over the material's yield stress. Then, a finite element model based on the surface–core approach was fitted to experimental results and the study was extended to analyse the influence of load level, degree of work-hardening and initial surface conditions. For the studied case, initial tensile surface residual stress (776 MPa) became even more tensile when applying loads higher than the material yield stress, but a shift was observed at the highest applied load (1350 MPa) and initial residual stress was relaxed about 170 MPa. This particular behaviour is associated to the modified stress–strain properties of the machined affected surface layer which was strongly work-hardened. Moreover, if the work-hardened properties are not considered in the finite element model results differ substantially from experiments. Surface residual stress stability also depends on the initial surface residual stress, but the degree of work-hardening induced by the machining process must be considered as well. If the difference between the yield stress of the surface and the yield stress of the core is lower than the initial surface residual stress, the surface begins yielding first and consequently the surface residual stress is decreased. In contrast, if the difference between the yield stress of the surface and the

  6. Stability of machining induced residual stresses in Inconel 718 under quasi-static loading at room temperature

    Energy Technology Data Exchange (ETDEWEB)

    Madariaga, A., E-mail: amadariaga@mondragon.edu [Mechanical and Industrial Production Department, Faculty of Engineering, Mondragon Unibertsitatea, Loramendi 4, Mondragon 20500 Gipuzkoa (Spain); Esnaola, J.A.; Arrazola, P.J. [Mechanical and Industrial Production Department, Faculty of Engineering, Mondragon Unibertsitatea, Loramendi 4, Mondragon 20500 Gipuzkoa (Spain); Ruiz-Hervias, J.; Muñoz, P. [Departamento Ciencia de Materiales, ETSI Caminos, Universidad Politécnica de Madrid, c/Profesor Aranguren s/n, Madrid 28040 (Spain); Ostolaza, K. [Materials and Processes Technology Department, ITP S.A., Parque Tecnológico, Edificio 300, 48170 Zamudio (Spain)

    2015-01-03

    Tensile residual stresses are very often generated on the surface when machining nickel alloys. In order to determine their influence on the final mechanical behaviour of the component residual stress stability should be considered. In the present work the evolution of surface residual stresses induced by machining in Inconel 718 under static loading at room temperature was studied experimentally and numerically. An Inconel 718 disc was face turned employing industrial working conditions and specimens for tensile tests were extracted from the disc. Surface residual stresses were measured by X-ray diffraction for initial state and after applying different loads over the material's yield stress. Then, a finite element model based on the surface–core approach was fitted to experimental results and the study was extended to analyse the influence of load level, degree of work-hardening and initial surface conditions. For the studied case, initial tensile surface residual stress (776 MPa) became even more tensile when applying loads higher than the material yield stress, but a shift was observed at the highest applied load (1350 MPa) and initial residual stress was relaxed about 170 MPa. This particular behaviour is associated to the modified stress–strain properties of the machined affected surface layer which was strongly work-hardened. Moreover, if the work-hardened properties are not considered in the finite element model results differ substantially from experiments. Surface residual stress stability also depends on the initial surface residual stress, but the degree of work-hardening induced by the machining process must be considered as well. If the difference between the yield stress of the surface and the yield stress of the core is lower than the initial surface residual stress, the surface begins yielding first and consequently the surface residual stress is decreased. In contrast, if the difference between the yield stress of the surface and the

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

    Science.gov (United States)

    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.

  8. A new method of residual stress distribution analysis for corroded Zircaloy-4 cladding

    International Nuclear Information System (INIS)

    Godlewski, J.; Cadalbert, R.

    1992-01-01

    An X-ray diffraction method of residual stress measurement is developed to determine the stress level in the metal near the metal/oxide interface of Zircaloy-4 cladding samples oxidized in steam water at 400degC under a pressure of 10.3 MPa. The stress gradient is obtained and the evolution of the average stress is determined as function of the oxidation time. The presence of tetragonal zirconia phase in quite large quantity near the metal/oxide interface could be correlated to the high stress level in the base metal, adjacent to the interface. (author)

  9. A new method for residual stress distribution - analysis of corroded zircaloy-4 cladding

    International Nuclear Information System (INIS)

    Godlewski, J.; Cadalbert, R.

    1992-01-01

    An X-ray diffraction method for residual stress measurement is developed to determine the stress level in the metal near the metal/oxide interface of Zircaloy-4 cladding samples oxidized in steam water at 400 deg C under a pressure of 10.3 MPa. The stress gradient is obtained and the evolution of the average stress is determined as a function of the oxidation time. The presence of tetragonal zirconia phase in quite large quantity near the metal/oxide interface could be correlated to the high stress level in the base metal, adjacent to the interface. 12 refs., 5 figs., 1 tab

  10. Macroscopic and microscopic determinations of residual stresses in thin oxide dispersion strengthened steel tubes

    International Nuclear Information System (INIS)

    Bechade, J.L.; Toualbi, L.; Bosonnet, S.; Carlan, Y. de; Castelnau, O.

    2014-01-01

    To improve the efficiency of components operating at high temperatures, many efforts are deployed to develop new materials. Oxide Dispersion Strengthened (ODS) materials could be used for heat exchangers or cladding tubes for the new GENIV nuclear reactors. This type of materials are composed with a metallic matrix (usually iron base alloy for nuclear applications or nickel base alloy for heat exchangers) reinforced by a distribution of nano-oxides. They are obtained by powder metallurgy and mechanical alloying. The creep resistance of these materials is excellent, and they usually exhibit a high tensile strength at room temperature. Depending on the cold working and/or the heat treatments, several types of microstructure can be obtained: recrystallised, stress relieved. One of the key challenges is to transform ODS materials into thin tubes (up to 500 microns thick) within a robust fabrication route while keeping the excellent mechanical properties. To prevent cracking during the process or to obtain a final product with low residual stresses, it is important to quantify the effect of the heat treatments on the release of internal stresses. The aim of this study is to show how residual stresses can be determined on different thin tubes using two complementary approaches: (i) macroscopic stresses determination in the tube using beam theory (small cuts along the longitudinal and circumferential directions and measurements of the deflection), (ii) stress determination from x-ray diffraction analyses (surface analyses, using 'sin"2ψ' method with different hypothesis). Depending on the material and the heat treatment, residual stresses vary dramatically and can reach 800 MPa which is not far from the yield stress; comparisons between both methods are performed and suggestions are given in order to optimize the thermo-mechanical treatment of thin ODS tubes. (authors)

  11. A strategy for accommodating residual stresses in the assessment of repair weldments based upon measurement of near surface stresses

    International Nuclear Information System (INIS)

    Mcdonald, E.J.; Hallam, K.R.; Flewitt, P.E.J.

    2005-01-01

    On many occasions repairs are undertaken to ferritic steel weldments on plant either during construction or to remove service induced defects. These repaired weldments are subsequently put into service with or without a post-weld heat treatment. In either case, but particularly for the latter, there is a need to accommodate the associated residual stresses in structural integrity assessments such as those based upon the R6 failure avoidance procedure. Although in some circumstances the residual macro-stresses developed within weldments of components and structures can be calculated this is not so readily achieved in the case of residual stresses introduced by repair welds. There is a range of physical and mechanical techniques available to undertake the measurement of macro-residual stresses. Of these X-ray diffraction has the advantage that it is essentially non-destructive and offers the potential for evaluating stresses, which exist in the near surface layer. Although for many structural integrity assessments both the magnitude and distribution of residual stresses have to be accommodated it is not practical to make destructive measurements on weld repaired components and structures to establish the through section distribution of stresses. An approach is to derive a description of the appropriate macro-stresses by a combination of measurement and calculation on trial ferritic steel repair weldments. Surface measurements on the plant can then be made to establish the relationship between the repaired component or structure and the trial weld and thereby improve confidence in predicted stresses and their distribution from the near-surface measured values. Hence X-ray diffraction measurements at the near-surface of the plant weldment can be used to underwrite the quality of the repair by confirming the magnitude and distribution of residual stresses used for the integrity assessment to demonstrate continued safe operation

  12. A primary simulation for residual stress neutron diffractometer

    International Nuclear Information System (INIS)

    Wang Shuying; Liu Lijuan; Sun Liangwei

    2012-01-01

    At present, neutron diffraction method is the unique and nondestructive method that can directly measure the residual stress distribution in deep materials and engineering components. It has an important application in engineering. A simulation of the flux at the position of the sample table was reported, and the resolution of the residual stress instrument was computed at the same time. The effect of the parameters of the second collimator on the flux at the sample position and the resolution of the instrument have been analyzed. The result indicated that the second collimator empress much on the neutron flux and the instrument resolution is well when the sample's diffraction angle is less than 120°. (authors)

  13. A generic approach for a linear elastic fracture mechanics analysis of components containing residual stress

    International Nuclear Information System (INIS)

    Lee, Hyeong Y.; Nikbin, Kamran M.; O'Dowd, Noel P.

    2005-01-01

    A review of through thickness transverse residual stress distribution measurements in a number of components, manufactured from a range of steels, has been carried out. Residual stresses introduced by welding and mechanical deformation have been considered. The geometries consisted of welded T-plate joints, pipe butt joints, tube-on-plate joints, tubular Y-joints and tubular T-joints as well as cold bent tubes and repair welds. In addition, the collected data cover a range of engineering steels including ferritic, austenitic, C-Mn and Cr-Mo steels. The methods used to measure the residual stresses also varied. These included neutron diffraction, X-ray diffraction and deep hole drilling techniques. Measured residual stress data, normalised by their respective yield stress have shown an inverse linear correlation versus the normalised depth of the region containing the residual stress (up to 0.5 of the component thickness). A simplified generic residual stress profile based on a linear fit to the data is proposed for the case of a transverse residual tensile stress field. Whereas the profiles in assessment procedures are case specific the proposed linear profile can be varied to produce a combination of membrane and bending stress distributions to give lower or higher levels of conservatism on stress intensity factors, depending on the amount of case specific data available or the degree of safety required

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

    Science.gov (United States)

    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.

  15. Prediction of residual stresses in electron beam welded Ti-6Al-4V plates

    Energy Technology Data Exchange (ETDEWEB)

    Xu, Lianyong; Ge, Keke; Jing, Hongyang; Zhao, Lei; Lv, Xiaoqing [Tianjin Univ. (China); Han, Yongdian [Tianjin Univ. (China). Key Lab. of Advanced Joining Technology

    2017-05-01

    A thermo-metallurgical procedure based on the SYSWELD code was developed to predict welding temperature field, microstructure and residual stress in butt-welded Ti-6Al-4V plate taking into account phase transformation. The formation of martensite was confirmed by the CCT diagram and microstructure in the weld joint, which significantly affects the magnitude of residual stress. The hole drilling procedure was utilized to measure the values of residual stress at the top surface of the specimen, which are in well agreement with the numerical results. Both simulated and test results show that the magnitude and distribution of residual stress on the surface of the plate present a large gradient feature from the weld joint to the base metal. Moreover, the distribution law of residual stresses in the plate thickness was further analyzed for better understanding of its generation and evolution.

  16. Effect of temperature on cyclic deformation behavior and residual stress relaxation of deep rolled under-aged aluminium alloy AA6110

    International Nuclear Information System (INIS)

    Juijerm, P.; Altenberger, I.

    2007-01-01

    Mechanical surface treatment (deep rolling) was performed at room temperature on the under-aged aluminium wrought alloy AA6110 (Al-Mg-Si-Cu). Afterwards, specimens were cyclically deformed at room and elevated temperatures up to 250 deg. C. The cyclic deformation behavior and s/n-curves of deep rolled under-aged AA6110 were investigated by stress-controlled fatigue tests and compared to the as-polished condition as a reference. The stability of residual stresses as well as diffraction peak broadening under high-loading and/or elevated-temperature conditions was investigated by X-ray diffraction methods before and after fatigue tests. Depth profiles of near-surface residual stresses as well as full width at half maximum (FWHM) values before and after fatigue tests at elevated temperatures are presented. Thermal residual stress relaxation of deep rolled under-aged AA6110 was investigated and analyzed by applying a Zener-Wert-Avrami function. Thermomechanical residual stress relaxation was analyzed through thermal residual stress relaxation and depth profiles of residual stresses before and after fatigue tests. Finally, an effective border line for the deep rolling treatment due to instability of near-surface work hardening was found and established in a stress amplitude-temperature diagram

  17. Prediction of Weld Residual Stress of Narrow Gap Welds

    International Nuclear Information System (INIS)

    Yang, Jun Seog; Huh, Nam Su

    2010-01-01

    The conventional welding technique such as shield metal arc welding has been mostly applied to the piping system of the nuclear power plants. It is well known that this welding technique causes the overheating and welding defects due to the large groove angle of weld. On the other hand, the narrow gap welding(NGW) technique has many merits, for instance, the reduction of welding time, the shrinkage of weld and the small deformation of the weld due to the small groove angle and welding bead width comparing with the conventional welds. These characteristics of NGW affect the deformation behavior and the distribution of welding residual stress of NGW, thus it is believed that the residual stress results obtained from conventional welding procedure may not be applied to structural integrity evaluation of NGW. In this paper, the welding residual stress of NGW was predicted using the nonlinear finite element analysis to simulate the thermal and mechanical effects of the NGW. The present results can be used as the important information to perform the flaw evaluation and to improve the weld procedure of NGW

  18. Residual stresses associated with the hydraulic expansion of steam generator tubing into tubesheets

    International Nuclear Information System (INIS)

    Middlebrooks, W.B.; Harrod, D.L.; Gold, R.E.

    1993-01-01

    Various methods are being used to expand heat transfer tubes into the thick tubesheets of nuclear steam generators. The residual stresses in the as-expanded tubes and methods for reducing these stresses are important because of the role which residual stresses play in stress corrosion cracking and stress assisted corrosion of the tubing. Of the various expansion processes, the hydraulic expansion process is most amenable to analytical study. This paper presents results on the residual stresses and strains in hydraulically expanded tubes and the tubesheet as computed by two different finite element codes with three different finite element models and by a theoretical incremental analysis method. The calculations include a sensitivity analysis to assess the effects of the expansion variables and the effect of stress relief heat treatments. (orig.)

  19. Effect of Plastic Pre-straining on Residual Stress and Composition Profiles in Low-Temperature Surface-Hardened Austenitic Stainless Steel

    DEFF Research Database (Denmark)

    Bottoli, Federico; Christiansen, Thomas Lundin; Winther, Grethe

    2016-01-01

    The present work deals with the evaluation of the residual stress profiles in expanded austenite by applying grazing incidence X-ray diffraction (GI-XRD) combined with successive sublayer removal. Annealed and deformed (εeq=0.5) samples of stable stainless steel EN 1.4369 were nitrided...... or nitrocarburized. The residual stress profiles resulting from the thermochemical low-temperature surface treatment were measured. The results indicate high-residual compressive stresses of several GPa’s in the nitrided region, while lower-compressive stresses are produced in the carburized case. Plastic...... deformation in the steel prior to thermochemical treatment has a hardly measurable influence on the nitrogen-rich zone, while it has a measurable effect on the stresses and depth of the carbon-rich zone....

  20. Grain size influence on residual stresses in alumina/zirconia composites

    International Nuclear Information System (INIS)

    Sergo, V.; Sbaizero, O.; Pezzotti, G.; Nishida, T.

    1998-01-01

    The grain size (GS) and volume fraction of alumina have been systematically varied in composites with a zirconia matrix and the corresponding residual stresses have been assessed by means of piezospectroscopy. The compressive stress in alumina depends on the volume fraction and it is well predicted by a stochastic model based on information theory. No dependence with GS has been detected, except at the highest volume content (20% vol. alumina). Conversely the stress distribution is independent from the volume fraction and depends on GS: intermediate values of GS exhibit the wider stress distribution. The tensile stress in zirconia shows no clear correlation with the volume fraction and increases with increasing zirconia GS. This latter behavior has been compared with a model based on diffusion relaxation of stresses. The model reproduces correctly the stress change due to different alumina contents, but it diverges from the experimental data at smaller GSs, overestimating the residual stress. It is suggested that grain boundary sliding may also contribute to the relaxation of stresses

  1. Diffraction Plane Dependence of Micro Residual Stresses in Uniaxially Extended Carbon Steels

    Directory of Open Access Journals (Sweden)

    T. Hanabusa

    2010-12-01

    Full Text Available In the stress measurement using X-ray or neutron diffraction, an elastic anisotropy as well as a plastic anisotropy of crystal must be carefully considered. In the X-ray and neutron diffraction stress measurement for polycrystalline materials, a particular {hkl} plane is used in measuring lattice strains. The dependence of an X-ray elastic constant on a diffraction plane is a typical example caused by an elastic anisotropy of the crystal. The yield strength and the work hardening rate of a single crystal depend on a crystallographic direction of the crystal. The difference in the yield strength and the work hardening rate relating to the crystallographic direction develops different residual stresses measured on each {hkl} diffraction after plastic deformation of a polycrystalline material. The present paper describes the result of the neutron stress measurement on uniaxially extended low and middle carbon steels. A tri-axial residual stress state developed in the extended specimens was measured on different kind of {hkl} diffraction plane. The measurement on the {110}, {200} and {211} diffraction showed that residual stresses increased with increasing the plastic elongation and the residual stresses on {110} were compressive, {200} were tensile and those on {211} were the middle of the former two planes.

  2. Thermal Aging Effects on Residual Stress and Residual Strain Distribution on Heat Affected Zone of Alloy 600 in Dissimilar Metal Weld

    Energy Technology Data Exchange (ETDEWEB)

    Ham, Junhyuk; Choi, Kyoung Joon; Kim, Ji Hyun [UNIST, Ulsan (Korea, Republic of)

    2016-10-15

    Dissimilar metal weld (DMW), consisting of Alloy 600, Alloy 182, and A508 Gr.3, has been widely used as a joining material of the reactor pressure vessel penetration nozzle and the steam generator tubing for pressurized water reactors (PWR) because of its good mechanical strength, thermal conductivity, and corrosion resistance. Residual tensile stress is mainly nominated as a cause of SCC in light water reactors by IAEA report. So, to relax the residual stress, post-weld heat treatment is required after manufacturing process such as welding. However, thermal treatment has a great effect on the microstructure and the chromium depletion profile on Alloy 600, so called sensitization. By this reason, HAZ on Alloy 600 is critical to crack. According to G.A. Young et al., Crack growth rates (CGR) in the Alloy 600 HAZ were about 30 times faster than those in the Alloy 600 base metal tested under the same conditions. And according to Z.P. Lu et al., CGR in the Alloy 600 HAZ can be more than 20 times higher than that in its base metal. There are some methods to measure the exact value of residual stress on the material surface. The most common way is X-ray diffraction method (XRD). The principle of XRD is based on lattice strains and depends on the changes in the spacing of the atomic planes in material. And there is a computer simulation method to estimate residual stress distribution which is called ANSYS. This study was conducted to investigate how thermal aging affects residual stress and residual strain distribution of Alloy 600 HAZ. Following conclusions can be drawn from this study. According to preceding researches and this study, both the relaxation of residual stress and the change of residual strain follow as similar way, spreading out from concentrated region. The result of Vickers micro-hardness tester shows that tensile residual stresses are distributed broadly on the material aged by 15 years. Therefore, HT400{sub Y}15 material is weakest state for PWSCC. The

  3. Residual stress evaluation and curvature behavior of aluminium 7050 peen forming processed

    International Nuclear Information System (INIS)

    Oliveira, R.R. de; Lima, N.B.; Braga, A.P.V.; Goncalves, M.

    2010-01-01

    Shot peening is a superficial cold work process used to increase the fatigue life evaluated by residual stress measurements. The peen forming process is a variant of the shot peening process, where a curvature in the plate is obtained by the compression of the grains near to the surface. In this paper, the influence of the parameters such as: pressure of shot, ball shot size and thickness of aluminum 7050 samples with respect to residual stress profile and resulting arc height was studied. The evaluation of the residual stress profile was obtained by sin 2 Ψ method. (author)

  4. Origin of high carrier mobility and low residual stress in RF superimposed DC sputtered Al doped ZnO thin film for next generation flexible devices

    Science.gov (United States)

    Kumar, Naveen; Dubey, Ashish; Bahrami, Behzad; Venkatesan, S.; Qiao, Qiquan; Kumar, Mukesh

    2018-04-01

    In this work, the energy and flux of high energetic ions were controlled by RF superimposed DC sputtering process to increase the grain size and suppress grain boundary potential with minimum residual stress in Al doped ZnO (AZO) thin film. AZO thin films were deposited at different RF/(RF + DC) ratios by keeping total power same and were investigated for their electrical, optical, structural and nanoscale grain boundaries potential. All AZO thin film showed high crystallinity and orientation along (002) with peak shift as RF/(RF + DC) ratio increased from 0.0, pure DC, to 1.0, pure RF. This peak shift was correlated with high residual stress in as-grown thin film. AZO thin film grown at mixed RF/(RF + DC) of 0.75 showed high electron mobility, low residual stress and large crystallite size in comparison to other AZO thin films. The nanoscale grain boundary potential was mapped using Kelvin Probe Force Microscopy in all AZO thin film and it was observed that carrier mobility is controlled not only by grains size but also by grain boundary potential. The XPS analysis confirms the variation in oxygen vacancies and zinc interstitials which explain the origin of low grain boundaries potential and high carrier mobility in AZO thin film deposited at 0.75 RF/(RF + DC) ratio. This study proposes a new way to control the grain size and grain boundary potential to further tune the optoelectronic-mechanical properties of AZO thin films for next generation flexible and optoelectronic devices.

  5. Residual stresses associated with welds in austenitic steel

    International Nuclear Information System (INIS)

    Fidler, R.

    1978-01-01

    Two exploratory welds have been made with AISI 316 austenitic steel and Armex GT electrodes by the manual metal-arc process, and residual stress measurements made in the as-welded condition and after various periods of stress relief. The results show that substantial stress relief occurs at temperatures of 850 0 and 750 0 C after 1 hr, but is not complete. The stress distributions are compared with those obtained from ferritic welds and the effect of differences in thermal expansion coefficients is examined using finite element analysis. (author)

  6. The effect of residual thermal stresses on the fatigue crack growth of laser-surface-annealed AISI 304 stainless steel Part I: computer simulation

    International Nuclear Information System (INIS)

    Shiue, R.K.; Chang, C.T.; Young, M.C.; Tsay, L.W.

    2004-01-01

    The effect of residual thermal stresses on the fatigue crack growth of the laser-surface-annealed AISI 304 stainless steel, especially the effect of stress redistribution ahead of the crack tip was extensively evaluated in the study. Based on the finite element simulation, the longitudinal residual tensile stress field has a width of roughly 20 mm on the laser-irradiated surface and was symmetric with respect to the centerline of the laser-annealed zone (LAZ). Meanwhile, residual compressive stresses distributed over a wide region away from the LAZ. After introducing a notch perpendicular to the LAZ, the distribution of longitudinal residual stresses became unsymmetrical about the centerline of LAZ. High residual compressive stresses exist within a narrow range ahead of notch tip. The improved crack growth resistance of the laser-annealed specimen might be attributed to those induced compressive stresses. As the notch tip passed through the centerline of the LAZ, the residual stress ahead of the notch tip was completely reverted into residual tensile stresses. The existence of unanimous residual tensile stresses ahead of the notch tip was maintained, even if the notch tip extended deeply into the LAZ. Additionally, the presence of the residual tensile stress ahead of the notch tip did not accelerate the fatigue crack growth rate in the compact tension specimen

  7. The effect of residual stress relaxation by the vibratory stress relief technique on the textures of grains in AA 6061 aluminum alloy

    Energy Technology Data Exchange (ETDEWEB)

    Wang, Jia-Siang; Hsieh, Chih-Chun; Lin, Chi-Ming; Chen, Erh-Chiang; Kuo, Che-Wei; Wu, Weite, E-mail: wwu@dragon.nchu.edu.tw

    2014-05-01

    The textures and crystallographic orientations beneath the treatment area in AA 6061 aluminum alloy after vibratory stress relief (VSR) process were investigated by combining the electron backscatter diffraction analysis of the misoriented low- or high-angle boundaries, the (inverse) pole figures, the line scans and the various grain orientations. The relaxation effect caused by compressive residual stress in the intermediate region is superior to that of tensile residual stress on both sides of the cantilever by means of X-ray diffraction techniques. The residual stress relaxation that occurs due to vibrational stress excitation accompanies the “orientation of banding” disintegration, the decreases in the dislocation density, the strain energy, and the fraction of low-angle boundaries within each type of grain orientation, such as Copper {112} 〈111〉, S {123} 〈634〉, Goss {110} 〈001〉, and Brass {110} 〈112〉, excepting the Cube (or near-Cube) {100} 〈001〉 grain orientation. The maintained invariance in the Cube texture can be attributed to the maximum number of active primary slip systems, resulting in an interaction that results from hindered slip on intersecting families of the planes.

  8. The effect of residual stress relaxation by the vibratory stress relief technique on the textures of grains in AA 6061 aluminum alloy

    International Nuclear Information System (INIS)

    Wang, Jia-Siang; Hsieh, Chih-Chun; Lin, Chi-Ming; Chen, Erh-Chiang; Kuo, Che-Wei; Wu, Weite

    2014-01-01

    The textures and crystallographic orientations beneath the treatment area in AA 6061 aluminum alloy after vibratory stress relief (VSR) process were investigated by combining the electron backscatter diffraction analysis of the misoriented low- or high-angle boundaries, the (inverse) pole figures, the line scans and the various grain orientations. The relaxation effect caused by compressive residual stress in the intermediate region is superior to that of tensile residual stress on both sides of the cantilever by means of X-ray diffraction techniques. The residual stress relaxation that occurs due to vibrational stress excitation accompanies the “orientation of banding” disintegration, the decreases in the dislocation density, the strain energy, and the fraction of low-angle boundaries within each type of grain orientation, such as Copper {112} 〈111〉, S {123} 〈634〉, Goss {110} 〈001〉, and Brass {110} 〈112〉, excepting the Cube (or near-Cube) {100} 〈001〉 grain orientation. The maintained invariance in the Cube texture can be attributed to the maximum number of active primary slip systems, resulting in an interaction that results from hindered slip on intersecting families of the planes

  9. Novel approaches to determining residual stresses by ultramicroindentation techniques: Application to sandblasted austenitic stainless steel

    International Nuclear Information System (INIS)

    Frutos, E.; Multigner, M.; Gonzalez-Carrasco, J.L.

    2010-01-01

    This research addresses the determination of residual stresses in sandblasted austenitic steel by ultramicroindentation techniques using a sharp indenter, of which the sensitivity to residual stress effects is said to be inferior to that of spherical ones. The introduction of an angular correction in the model of Wang et al. which relates variations in the maximum load to the presence of residual stresses is proposed. Similarly, the contribution to the hardness of grain size refinement and work hardening, developed as a consequence of the severe plastic deformation during blasting, is determined in order to avoid overestimation of the residual stresses. Measurements were performed on polished cross sections along a length of several microns, thus obtaining a profile of the residual stresses. Results show good agreement with those obtained by synchrotron radiation on the same specimens, which validates the method and demonstrates that microindentation using sharp indenters may be sensitive to the residual stress effect.

  10. Novel approaches to determining residual stresses by ultramicroindentation techniques: Application to sandblasted austenitic stainless steel

    Energy Technology Data Exchange (ETDEWEB)

    Frutos, E. [Centro de Bioingenieria, Biomateriales y Nanomedicina, CIBER-BBN, Instituto de Salud Carlos III (Spain)] [Centro Nacional de Investigaciones Metalurgicas, CENIM-CSIC, 28040 Madrid (Spain); Multigner, M. [Centro Nacional de Investigaciones Metalurgicas, CENIM-CSIC, 28040 Madrid (Spain)] [Centro de Bioingenieria, Biomateriales y Nanomedicina, CIBER-BBN, Instituto de Salud Carlos III (Spain); Gonzalez-Carrasco, J.L., E-mail: jlg@cenim.csic.es [Centro Nacional de Investigaciones Metalurgicas, CENIM-CSIC, 28040 Madrid (Spain)] [Centro de Bioingenieria, Biomateriales y Nanomedicina, CIBER-BBN, Instituto de Salud Carlos III (Spain)

    2010-07-15

    This research addresses the determination of residual stresses in sandblasted austenitic steel by ultramicroindentation techniques using a sharp indenter, of which the sensitivity to residual stress effects is said to be inferior to that of spherical ones. The introduction of an angular correction in the model of Wang et al. which relates variations in the maximum load to the presence of residual stresses is proposed. Similarly, the contribution to the hardness of grain size refinement and work hardening, developed as a consequence of the severe plastic deformation during blasting, is determined in order to avoid overestimation of the residual stresses. Measurements were performed on polished cross sections along a length of several microns, thus obtaining a profile of the residual stresses. Results show good agreement with those obtained by synchrotron radiation on the same specimens, which validates the method and demonstrates that microindentation using sharp indenters may be sensitive to the residual stress effect.

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

    Energy Technology Data Exchange (ETDEWEB)

    Lewis, John R. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Brooks, Dusty Marie [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

    2016-10-01

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

  12. Residual stresses and strength of multilayer tape cast solid oxide fuel and electrolysis half-cells

    DEFF Research Database (Denmark)

    Charlas, Benoit; Frandsen, Henrik Lund; Brodersen, Karen

    2015-01-01

    those with 3 layers (MTC3: without barrier layer). The bending strength of MTC3 and MTC4 under various loading orientations (electrolyte on the tensile or compressive side of the loading) is compared. The analysis, by taking residual stresses into account, shows that the strength of the half...... coefficient (TEC) mismatch between the layers, cumulated from high temperature, induces significant residual stresses in the half-cells. Furthermore, it has been observed that MTC half-cells with 4 layers (MTC4: support, fuel electrode, electrolyte and barrier layer) are sometimes more fragile to handle than...... stresses, especially in the outer barrier-layer, possible changes to the layer properties are discussed and some optimization guidelines proposed....

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

    Science.gov (United States)

    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.

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

    International Nuclear Information System (INIS)

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

    2013-01-01

    High energy synchrotron XRD was employed to determine the lattice strain ε{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 ε{111}–cos 2 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

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

    Science.gov (United States)

    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.

  16. Influence of residual stress on diffusion-induced bending in bilayered microcantilever sensors

    International Nuclear Information System (INIS)

    Xuan Fuzhen; Shao Shanshan; Wang Zhengdong; Tu Shantung

    2010-01-01

    The influence of residual stress on diffusion-induced bending in bilayered microcantilever sensors has been analyzed under the framework of thermodynamic theory and Fick's second law. A self-consistent diffusion equation involving the coupling effects of residual stress and diffusion-induced stress is developed. Effects of thickness ratio, modulus ratio, diffusivity ratio and residual stress gradient of film and substrate on the curvature of bilayered cantilever are then discussed with the help of finite difference method. Results reveal that the curvature of bilayered cantilever increases with decreasing the diffusivity ratio and modulus ratio of substrate to film at a given time. Case study of the polysilicon/palladium hydrogen sensor has been finally carried out using the above developed bending theory.

  17. Fatigue behaviour of 304L steel welded structures: influence of residual stresses and surface mechanical finishing

    International Nuclear Information System (INIS)

    Magnier-Monin, L.

    2007-12-01

    This study focuses on the influence of residual stresses and surface mechanical finishing on lifetime of stainless steel 304L welded structures. Residual stresses are determined on specific specimens of three types: base-metal, as-welded and ground-welded specimens. Each type is submitted to fatigue tests in order to assess the influence of these parameters on the lifetime, and to determine their evolution. The experiments show that an important surface stress concentration is located in the weld root of as-welded structures, which has a negative effect on the fatigue life. The grinding operation generates high-level surface residual stresses but the lifetime is higher thanks to the reduction of the notch effect. The fatigue test results are compared to the nuclear industry best-fit S-N curves. This enables the determination of correction factors related to fatigue test results of polished specimens, and to assess the lifetime of structures. (author)

  18. Residual stress change by thermal annealing in amorphous Sm-Fe-B thin films

    International Nuclear Information System (INIS)

    Na, S.M.; Suh, S.J.; Kim, H.J.; Lim, S.H.

    2002-01-01

    The change in the residual stress and its effect on mechanical bending and magnetic properties of sputtered amorphous Sm-Fe-B thin films are investigated as a function of annealing temperature. Two stress components of intrinsic compressive stress and tensile stress due to the difference of the thermal expansion coefficients between the substrate and thin film are used to explain the stress state in as-deposited thin films, and the annealing temperature dependence of residual stress, mechanical bending and magnetic properties

  19. Evaluation of cladding residual stresses in clad blocks by measurements and numerical simulations

    International Nuclear Information System (INIS)

    Dupas, P.; Moinereau, D.

    1996-01-01

    Reactor pressure vessels are internally clad with austenitic stainless steel. This welding operation generates residual stresses which can have an important role in integrity assessments. In order to evaluate these stresses, an experimental and numerical programme has been conducted. The experiments includes cladding operations, macrographic analyses, temperature and residual stresses measurements with different methods. According to these measurements, transversal stresses (perpendicular to the welding direction) and longitudinal stresses (parallel to the welding direction) are highly tensile in stainless steel and they are compressive in the HAZ. Finite element calculations were used to simulate both welding operations and post weld heat treatment. These calculations coupled the thermal, metallurgical and mechanical aspects in a 2D representation. Different models were studied including effect of generalised plane strain, transformation plasticity, creep and tempering. The transversal stresses calculated are similar to the measured ones, but the longitudinal stresses showed to be very sensitive to the model used. As expected because of the two-dimension model, the longitudinal stresses can't be well estimated. More work is needed to improve measurements of stresses in depth (important differences appeared between the different methods). A predictive model would be also very useful to determine the thermal loading which is at present dependant on measurements. A 3D calculation appears to be necessary to evaluate longitudinal stresses. (orig.)

  20. A comparison of residual stresses in built-up steel beams using hole-drilling method

    International Nuclear Information System (INIS)

    Nawafleh, M. A.; Hunaiti, Y. M.; Younes, R. M.

    2009-01-01

    Residual stresses have a significant effect on the stability resistance of metal building systems. An experimental program was conducted to measure these stresses in built-up steel beams using incremental hole-drilling method. The experimental results reveal that the predicted residual stress type of pattern for built-up I-sections with fillet welds on one side of the web is not the same as the pattern of residual stresses in built-up I-sections with fillet welds on both sides of the web

  1. Residual stress measurement by x-ray under the consideration of its penetration depth

    International Nuclear Information System (INIS)

    Doi, Osamu; Ukai, Takayoshi

    1983-01-01

    The authors derived the fundamental relations between the measured stress by X-ray and the residual stress distribution from the consideration of the contribution of internal stress in definite subsurface layer of metal to X-ray diffraction and proposed the exact formulas and their applications of residual stress measurements by successive thin layer removal in a plate, a hollow cylinder and a hollow sphere. (author)

  2. Influence of heat input and radius to pipe thickness ratio on the residual stresses in circumferential arc welded pipes of API X46 steels

    International Nuclear Information System (INIS)

    Hemmatzadeh, Majid; Moshayedi, Hessamoddin; Sattari-Far, Iradj

    2017-01-01

    The present work aims to study residual stresses caused by circumferentially welding of two similar API X46 steel pipes by means of finite element modeling. Considering the metallurgical phase transformations and through thermal-mechanical uncoupled analysis, the 3D modeling was carried out by SYSWELD software. Materialistic thermal and mechanical properties of all phases were defined in terms of temperature as well as phase transformation properties. Residual stress was measured through hole-drilling method. The obtained results were used to verify the finite element model. By means of full factorial experiment designing method, effects of heat input and radius to pipe thickness ratio on maximum values of hoop and axial residual stresses were investigated. The effect of each factor was studied in 3 levels and by 9 experiments. Results of statistical analysis revealed that increase in heat input and radius-thickness ratio would lead to higher values of maximum hoop and axial residual stresses. However, interactions of high level of heat input and a low level of radius-thickness ratio increased inter-pass temperature and consequently caused a sudden raise in maximum values of residual stresses. - Highlights: • A FEM model was developed to simulate welding considering phase transformations. • The obtained residual stresses were validated by experiments. • Effect of heat input and radius-to-thickness ratio on residual stress were investigated. • Increasing heat input for 100% caused increasing hoop and axial residual stress until 200%. • Interaction of high heat input and low R/t causes a sudden increase in axial residual stresses.

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

    International Nuclear Information System (INIS)

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

    2007-01-01

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

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

    Science.gov (United States)

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

    2007-03-01

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

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

    Science.gov (United States)

    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.

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

    Science.gov (United States)

    2014-03-01

    solidification cracking in steels and stainless steels . He has also undertaken extensive work on improving the weld zone toughness of high strength steels ...information on microstructural characterisation at the interface of ferritic- martensitic and austenitic steels produced using the EW process, the...957. [3] I. Tatsukawa, I. Oda, ‘Residual Stress Measurements on Explosive Clad Stainless Steel ’, Trans. Japan Welding Soc., 2(2), 1971, p26-34

  7. Origins of residual stress in Mo and Ta films: The role of impurities, microstructural evolution, and phase transformations

    International Nuclear Information System (INIS)

    Parfitt, L.J.; Karpenko, O.P.; Yalisove, S.M.; Bilello, J.C.

    1997-01-01

    Both the sign and magnitude of residual stress can vary with the thickness of sputter deposited films. The origins of this behavior are not well understood. In this work, the authors consider the correlation between the residual stress behavior and the depth dependence of impurities in thin (2.5 nm--150 nm) sputtered Mo and Ta films. They also consider the effects of phase transformations and microstructural changes on the stress behavior. Films were deposited onto Si substrates with native oxide. The residual stress observed in the Mo films varied from highly compressive at 2.5 nm film thickness to ∼0 at 10 nm thickness. Ta films also exhibited a high compressive stress, which relaxed from highly compressive to tensile between 10 nm and 50 nm film thickness. Impurities in the films may originate from the sputtering targets, the background gases, and the substrate surfaces. Auger Electron Spectroscopy (AES) results showed the presence of O and C contamination near the film/Si interface; these impurities contributed to the compressive stresses in the thinner films. As anticipated, both Mo and Ta films exhibited grain growth as a function of film thickness, which may have contributed to the relaxation in the compressive stress. The Mo films were entirely bcc. The Ta films showed a transformation from the amorphous phase to the β crystalline phase between 2.5 nm and 20 nm film thickness, which contributed to the relaxation in stress observed in that thickness regime

  8. Residual stress measurements in the dissimilar metal weld in pressurizer safety nozzle of nuclear power plant

    International Nuclear Information System (INIS)

    Campos, Wagner R.C.; Rabello, Emerson G.; Mansur, Tanius R.; Scaldaferri, Denis H.B.; Paula, Raphael G.; Souto, Joao P.R.S.; Carvalho Junior, Ideir T.

    2013-01-01

    Weld residual stresses have a large influence on the behavior of cracking that could possibly occur under normal operation of components. In case of an unfavorable environment, both stainless steel and nickel-based weld materials can be susceptible to stress-corrosion cracking (SCC). Stress corrosion cracks were found in dissimilar metal welds of some pressurized water reactor (PWR) nuclear plants. In the nuclear reactor primary circuit the presence of tensile residual stress and corrosive environment leads to so-called Primary Water Stress Corrosion Cracking (PWSCC). The PWSCC is a major safety concern in the nuclear power industry worldwide. PWSCC usually occurs on the inner surface of weld regions which come into contact with pressurized high temperature water coolant. However, it is very difficult to measure the residual stress on the inner surfaces of pipes or nozzles because of inaccessibility. A mock-up of weld parts of a pressurizer safety nozzle was fabricated. The mock-up was composed of three parts: an ASTM A508 C13 nozzle, an ASTM A276 F316L stainless steel safe-end, an AISI 316L stainless steel pipe and different filler metals of nickel alloy 82/182 and AISI 316L. This work presents the results of measurements of residual strain from the outer surface of the mock-up welded in base metals and filler metals by hole-drilling strain-gage method of stress relaxation. (author)

  9. NUMERICAL AND EXPERIMENTAL ANALYSIS OF RESIDUAL STRESSES GENERATED DURING HARDENING OFAISI 4140 BAR

    Directory of Open Access Journals (Sweden)

    Edwan Anderson Ariza Echeverri

    2012-09-01

    Full Text Available The aim of this work is to analyze the distribution of residual stresses resulting from the combination of volumetric changes due to heat gradients and phase changes occurring during the quenching process of an AISI/SAE 4140 steel cylinder. The mathematical model used for this objective is the AC3 modeling software of thermal treatments (transformation curves, cooling curves and microstructure, whose results were input in an finite element model, considering thermalmechanical coupling and non-linear elastic-plastic behavior, aiming the assessment of residual stresses in quenched 4140 steel cylinders. The observed microstructure confirms quantitatively and qualitatively the previsions of the AC3 Software. The results of the modeling are compared with the residual stresses measurements made using X-Ray diffraction techniques. The finite element numerical simulation shows the existence of 350 MPa compressive residual stresses in the surface region and indicates that the most significant stresses are tangential.

  10. Effect of substrate preheating temperature and coating thickness on residual stress in plasma sprayed hydroxyapatite coating

    International Nuclear Information System (INIS)

    Tang, Dapei

    2015-01-01

    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. (paper)

  11. Effects of fretting fatigue on the residual stress of shot peened Ti-6Al-4V samples

    International Nuclear Information System (INIS)

    Martinez, S.A.; Sathish, S.; Blodgett, M.P.; Mall, S.; Namjoshi, S.

    2005-01-01

    X-ray diffraction residual stress measurement has been utilized as nondestructive tool for the characterization of fretting fatigue damage in shot peened samples of Ti-6Al-4V. Prior to fretting fatigue damage, compressive residual stresses were found to be uniform over the entire face of the sample and independent of the measurement direction. After fretting fatigue, inside and in the vicinity of the fretting damage zone large relaxation of compressive residual stress was observed. An anisotropic residual stress distribution has been observed in the fretting fatigue damaged region. Residual stress measurements in interrupted fretting fatigue experiments showed that the relaxation of residual stress increases as the number of fretting fatigue cycles increase. The results are discussed in the light of their importance in establishing X-ray diffraction residual stress measurement technique as a nondestructive tool to characterize fretting fatigue damage

  12. Residual Stress Measurement of Coarse Crystal Grain in Aluminium Casting Alloy by Neutron Diffraction

    International Nuclear Information System (INIS)

    Nishida, Masayuki; Watanabe, Yoshitaka; Hanabusa, Takao

    2009-01-01

    Full text: Neutron stress measurement can detect strain and stress information in deep region because of large penetration ability of neutron beams. The present paper describes procedure and results in the residual stress measurement of aluminium casting alloy by neutron diffraction. Usually, the aluminium casting alloy includes the large crystal grains. The existence of large crystal grains makes it difficult to estimate the residual stresses in highly accuracy. In this study, the modified three axial method using Hook's equation was employed for neutron stress measurement. These stress measurements were performed under the two kinds of new techniques. One is a rocking curve method to calculate the principal strains in three directions. The peak profiles which appear discretely on rocking curves were translated to principle stresses by the Bragg law and the basic elastic theory. Another is the consideration of measurement positions and the edge effect in the neutron irradiated area (volume gage). The edge effect generates the errors of 2θ-peak position in the neutron stress measurement. In this study, the edge effect was investigated in detail by a small bit of copper single crystal. The copper bit was moved and scanned on three dimensionally within the gage volume. Furthermore, the average strains of symmetrical positions are measure by the sample turning at 180 degrees, because the error distributions of the 2θ-peak position followed to positions inside the gage volume. Form these results of this study, the residual stresses in aluminium casting alloy which includes the large crystal grains were possible to estimate by neutron stress measurement with the rocking curve method and the correction of the edge effect. (author)

  13. On the evaluation of residual stress and mechanical properties of FeCrBSi coatings by nanoindentation

    International Nuclear Information System (INIS)

    Zhu Lina; Xu Binshi; Wang Haidou; Wang Chengbiao

    2012-01-01

    Highlights: ► Ni/Al coating can reduce the mismatch degree between the coating and substrate. ► No obvious pile-up is observed for the nanoindents of the FeCrBSi coating. ► The higher the tensile residual stress, the lower the hardness and elastic modulus. - Abstract: In this paper, the residual stress in the plasma-sprayed FeCrBSi coating was determined by nanoindentation and X-ray diffraction (XRD). The XRD results showed that tensile residual stress was generated in the FeCrBSi coating, and the through-thickness values range between 40 MPa and 112 MPa. The residual stress measured by nanoindentation is 753 MPa. The difference between the XRD and nanoindentation results was discussed. It is found that the factors limiting the nanoindentation measurement of residual stress include the ‘sink-in’ deformation around the indenter, the roughness of the FeCrBSi coating, and the use of reference sample without residual stress. The above three factors lead to the over-prediction of residual stress by nanoindentation.

  14. Measurement of residual stress in materials using neutrons. Proceedings of a technical meeting

    International Nuclear Information System (INIS)

    2005-06-01

    One of the objectives of the IAEA's project on effective utilization of research reactors is to promote the use of the existing research reactors based on their capabilities and is implemented through workshops and technical meetings. Measurement of residual stress is one of the techniques that find wide applications in materials development and testing. The Technical Meeting on Measurement of Residual Stress Using Neutrons was organized to meet this objective. This publication is the outcome of the deliberations during the meeting and the presentations by the participants and is addressed to the research reactor managers, users and designers of facilities for reactor utilization. It will especially benefit those seeking to develop new facilities or upgrade the existing ones to enhance the utilization of their research reactors. Experts with a long experience in developing and using neutron beam instruments in high flux and medium flux research reactors participated in this technical meeting. They presented the design, development and utilization of the facilities at their respective centres and reviewed the current status of the residual stress measurements using neutron beams from research reactors. The sessions included brainstorming on the methodology and data analysis, characterization and standardization of the equipment and identifying the scope for further development. This publication refers to the determination of residual and/or applied stresses in polycrystalline materials using neutron diffraction technique. Stress is developed during the synthesis and use of materials such as alloys and compounds. Measurement of residual stress is essential to improve the quality of synthesized materials and diagnosis of failure and/or reliability of fabricated components. Neutron scattering has played an important role in studying structure and dynamics of condensed matter. Neutron scattering is a non-destructive technique and is useful for testing large samples. The

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

    Science.gov (United States)

    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.

  16. Residual stress investigation of copper plate and canister EB-Welds Complementary Results

    International Nuclear Information System (INIS)

    Gripenberg, H.

    2009-03-01

    The residual stresses in copper as induced by EB-welding were studied by specimens where the weld had two configurations: either a linear or a circumferential weld. This report contains the residual stress measurements of two plates, containing linear welds, and the full-scale copper lid specimen to which a hollow cylinder section had been joined by a circumferential EB-weld. The residual stress state of the EB-welded copper specimens was investigated by X-ray diffraction (XRD), hole drilling (HD) ring core (RC) and contour method (CM). Three specimens, canister XK010 and plates X251 and X252, were subjected to a thorough study aiming at quantitative determination of the residual stress state in and around the EB-welds using XRD for surface and HD and RC for spatial stress analysis. The CM maps one stress component over a whole cross section. The surface residual stresses measured by XRD represent the machined condition of the copper material. The XRD study showed that the stress changes towards compression close to the weld in the hollow cylinder, which indicates shrinkage in the hoop direction. According to the same analogy, the shrinkage in the axial direction is much smaller. The HD measurements showed that the stress state in the base material is bi-axial and, in terms of von Mises stress, 50 MPa for the plates and 20 MPa for the cylinder part of the canister. The stress state in the EB-welds of all specimens differs clearly from the stress state in the base material being more tensile, with higher magnitudes of von Mises stress in the plate than in the canister welds. The HD and RC results were obtained using linear elastic theory. The RC measurements showed that the maximum principal stress in the BM is close to zero near the surface and it becomes slightly tensile, 10 MPa, deeper under the surface. Welding pushed the general stress state towards tension with the maximum principal stress reaching 50 MPa, deeper than 5 mm below the surface in the weld. The

  17. Reduction of tensile residual stresses during the drawing process of tungsten wires

    International Nuclear Information System (INIS)

    Rodriguez Ripoll, Manel; Weygand, Sabine M.; Riedel, Hermann

    2010-01-01

    Tungsten wires are commonly used in the lighting industry as filaments for lamps. During the drawing process, the inhomogeneous deformation imparted by the drawing die causes tensile residual stresses at the wire surface in circumferential direction. These stresses have a detrimental effect for the wire because they are responsible for driving longitudinal cracks, known as splits. This work proposes two methods for reducing the residual stresses during wire drawing, namely applying an advanced die geometry and performing an inexpensive post-drawing treatment based on targeted bending operations. These two methods are analyzed with finite element simulations using material parameters obtained by mechanical tests on tungsten wires at different temperatures as input data. The computed results predict a substantial reduction of the circumferential residual stresses, thus reducing the risk of splitting.

  18. Simulation of distortion and residual stress in high pressure die casting – modelling and experiments

    International Nuclear Information System (INIS)

    Hofer, P; Kaschnitz, E; Schumacher, P

    2012-01-01

    Two individual high-pressure die-casting geometries were developed in order to study the influence of process parameters and different alloys on the distortion behaviour of castings. These geometries were a stress lattice and a V-shaped sample tending to form residual stress due to different wall thickness respectively by a deliberate massive gating system. In the experimental castings the influence of the most important process parameters such as die temperature and die opening time and the cooling regime was examined. The time evolution of process temperatures was measured using thermal imaging. The heat transfer coefficients were adapted to the observed temperature distributions. Castings were produced from the two alloys AlSi12 and AlSi10MnMg. The distortion of the castings was measured by means of a tactile measuring device. For the alloy AlSi10MnMg thermo-physical and thermo-mechanical data were obtained using differential scanning calorimetry, laser flash technique, dilatometry and tensile testing at elevated temperatures. These data were used for modelling the material behaviour of the AlSi10MnMg alloy in the numerical model while for the alloy AlSi12(Fe) literature data were used. Process and stress simulation were conducted using the commercial FEM software ANSYS Workbench. A survey on the results of the comparison between simulation and experiment is given for both alloys.

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

    Energy Technology Data Exchange (ETDEWEB)

    Heinle, R.A.; Hudson, B.C. [Lawrence Livermore National Lab., CA (United States); Hatch, M.A. Jr.

    1994-12-31

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

  20. Residual stress measurement by X-ray diffraction with the Gaussian curve method and its automation

    International Nuclear Information System (INIS)

    Kurita, M.

    1987-01-01

    X-ray technique with the Gaussian curve method and its automation are described for rapid and nondestructive measurement of residual stress. A simplified equation for measuring the stress by the Gaussian curve method is derived because in its previous form this method required laborious calculation. The residual stress can be measured in a few minutes, depending on materials, using an automated X-ray stress analyzer with a microcomputer which was developed in the laboratory. The residual stress distribution of a partially induction hardened and tempered (at 280 0 C) steel bar was measured with the Gaussian curve method. A sharp residual tensile stress peak of 182 MPa appeared right outside the hardened region at which fatigue failure is liable to occur

  1. X-ray fractography by using synchrotron radiation source. Residual stress distribution just beneath fatigue fracture surface

    International Nuclear Information System (INIS)

    Akita, Koichi; Yoshioka, Yasuo; Suzuki, Hiroshi; Sasaki, Toshihiko

    2000-01-01

    The residual stress distributions just beneath the fatigue fracture surface were measured using synchrotron radiation with three different wavelengths, i.e., three different penetration depths. The residual stress distributions were estimated from three kinds of diffraction data by the following process. First, a temporary residual stress distribution in the depth direction is assumed. Theoretical 2θ-sin 2 ψ diagrams for each wavelength, where each has a different penetration depth, are calculated by the cosψ method developed by one of the authors. The sum total of the differences between the theoretical and experimental values of the diffraction angle in 2θ-sin 2 ψ diagrams is calculated. This total value is minimized by changing the assumed stress distribution by the quasi-Newton optimization method. Finally, optimized 2θ-sin 2 ψ diagrams for each penetration depth and detailed stress distribution are determined. The true surface residual stress is obtained from this stress distribution. No effect of load ratio R (= P min /P max ) on the residual stresses of the fatigue fracture surfaces in low-carbon steels was observed when the sin 2 ψ method was used for stress measurement. However, the residual stresses became higher with increasing R when these were measured by the proposed method. On the basis of this, the stress intensity factor range, ΔK, can be estimated from the residual stress on the fatigue fracture surface. (author)

  2. Variation behavior of residual stress distribution by manufacturing processes in welded pipes of austenitic stainless steel

    International Nuclear Information System (INIS)

    Ihara, Ryohei; Hashimoto, Tadafumi; Mochizuki, Masahito

    2012-01-01

    Stress corrosion cracking (SCC) has been observed near heat affected zone (HAZ) of primary loop recirculation pipes made of low-carbon austenitic stainless steel type 316L in the nuclear power plants. For the non-sensitization material, residual stress is the important factor of SCC, and it is generated by machining and welding. In the actual plants, welding is conducted after machining as manufacturing processes of welded pipes. It could be considered that residual stress generated by machining is varied by welding as a posterior process. This paper presents residual stress variation due to manufacturing processes of pipes using X-ray diffraction method. Residual stress distribution due to welding after machining had a local maximum stress in HAZ. Moreover, this value was higher than residual stress generated by welding or machining. Vickers hardness also had a local maximum hardness in HAZ. In order to clarify hardness variation, crystal orientation analysis with EBSD method was performed. Recovery and recrystallization were occurred by welding heat near the weld metal. These lead hardness decrease. The local maximum region showed no microstructure evolution. In this region, machined layer was remained. Therefore, the local maximum hardness was generated at machined layer. The local maximum stress was caused by the superposition effect of residual stress distributions due to machining and welding. Moreover, these local maximum residual stress and hardness are exceeded critical value of SCC initiation. In order to clarify the effect of residual stress on SCC initiation, evaluation including manufacturing processes is important. (author)

  3. Residual stresses and critical diameter in vitreous matrix materials

    International Nuclear Information System (INIS)

    Mastelaro, Valmor R.; Zanotto, Edgar D.

    1995-01-01

    The present study was undertaken to test the validity of existing models for: i) the residual internal stresses which arise due to thermal and elastic mismatch in duplex systems, and ii) the critical particle diameter for spontaneous cracking. Partially crystallized 1,07 Na 2 O-2 Ca O-3 Si O 2 - 6% P 2 O 5 glasses were studied. The experimental residual stress was in excellent agreement with the calculated value, however, the critical particle diameter, estimated by an energy balance approach, was more than ten times smaller than the experimental value. This discrepancy indicates that the energy model is not applicable in this case. (author)

  4. Residual stress and mechanical properties of SiC ceramic by heat treatment

    International Nuclear Information System (INIS)

    Yoon, H.K.; Kim, D.H.; Shin, B.C.

    2007-01-01

    Full text of publication follows: Silicon carbide is a compound of relatively low density, high hardness, elevated thermal stability and good thermal conductivity, resulting in good thermal shock resistance. Because of these properties, SiC materials are widely used as abrasives and refractories. In this study, SiC single and poly crystals was grown by the sublimation method using the SiC seed crystal and SiC powder as the source material. Mechanical properties of SiC single and poly crystals are carried out by using the nano-indentation method and small punch test after the heat treatment. As a result, mechanical properties of SiC poly crystal had over double than single. And SiC single and poly crystals were occurred residual stress, but residual stress was shown relaxant properties by the effect of heat treatment. (authors)

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

    Science.gov (United States)

    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.

  6. Residual stress state in pipe cut ring specimens for fracture toughness testing

    Energy Technology Data Exchange (ETDEWEB)

    Damjanovic, Darko [J.J. Strossmayer Univ. of Osijek, Slavonski Brod (Croatia). Mechanical Engineering Faculty; Kozak, Drazan [Zagreb Univ. (Croatia). Dept. for Mechanical Design; Marsoner, Stefan [Materials Center, Leoben (Austria).; Gubeljak, Nenad [Maribor Univ. (Slovenia). Chair of Mechanics

    2017-07-01

    Thin-walled pipes are not suitable for measuring fracture toughness parameters of vital importance because longitudinal crack failure is the most common failure mode in pipes. This is due to the impossibility to manufacture standard specimens for measuring fracture toughness, such as SENB or CT specimens, from the thin wall of the pipe. Previous works noticed this problem, but until now, a good and convenient solution has not been found or developed. To overcome this problem, very good alternative solution was proposed, the so-called pipe ring notched bend specimen (PRNB) [1-5]. Until now, only the idealized geometry PRNB specimen is analyzed, i. e., a specimen which is not cut out from an actual pipe but produced from steel plate. Based on that, residual stresses are neglected along with the imperfections in geometry (elliptical and eccentricity). The aim of this research is to estimate the residual stress state(s) in real pipes used in the boiler industry produced by hot rolling technique. These types of pipes are delivered only in normalized condition, but not stress relieved. Therefore, there are residual stresses present due to the manufacturing technique, but also due to uneven cooling after the production process. Within this paper, residual stresses are estimated by three methods: the incremental hole drilling method (IHMD), X-ray diffraction (XRD) and the splitting method (SM). Knowing the residual stress state in the ring specimen, it is possible to assess their impact on fracture toughness measured on the corresponding PRNB specimen(s).

  7. Residual stress state in pipe cut ring specimens for fracture toughness testing

    International Nuclear Information System (INIS)

    Damjanovic, Darko; Kozak, Drazan; Marsoner, Stefan; Gubeljak, Nenad

    2017-01-01

    Thin-walled pipes are not suitable for measuring fracture toughness parameters of vital importance because longitudinal crack failure is the most common failure mode in pipes. This is due to the impossibility to manufacture standard specimens for measuring fracture toughness, such as SENB or CT specimens, from the thin wall of the pipe. Previous works noticed this problem, but until now, a good and convenient solution has not been found or developed. To overcome this problem, very good alternative solution was proposed, the so-called pipe ring notched bend specimen (PRNB) [1-5]. Until now, only the idealized geometry PRNB specimen is analyzed, i. e., a specimen which is not cut out from an actual pipe but produced from steel plate. Based on that, residual stresses are neglected along with the imperfections in geometry (elliptical and eccentricity). The aim of this research is to estimate the residual stress state(s) in real pipes used in the boiler industry produced by hot rolling technique. These types of pipes are delivered only in normalized condition, but not stress relieved. Therefore, there are residual stresses present due to the manufacturing technique, but also due to uneven cooling after the production process. Within this paper, residual stresses are estimated by three methods: the incremental hole drilling method (IHMD), X-ray diffraction (XRD) and the splitting method (SM). Knowing the residual stress state in the ring specimen, it is possible to assess their impact on fracture toughness measured on the corresponding PRNB specimen(s).

  8. Investigation into Variations of Welding Residual Stresses and Redistribution Behaviors for Different Repair Welding Widths

    International Nuclear Information System (INIS)

    Park, Chiyong; Lee, Hweesueng; Huh, Namsu

    2014-01-01

    In this study, we investigated the variations in welding residual stresses in dissimilar metal butt weld due to width of repair welding and re-distribution behaviors resulting from similar metal welding (SMW) and mechanical loading. To this end, detailed two-dimensional axi-symmetric finite element (FE) analyses were performed considering five different repair welding widths. Based on the FE results, we first evaluated the welding residual stress distributions in repair welding. We then investigated the re-distribution behaviors of the residual stresses due to SMW and mechanical loads. It is revealed that large tensile welding residual stresses take place in the inner surface and that its distribution is affected, provided repair welding width is larger than certain value. The welding residual stresses resulting from repair welding are remarkably reduced due to SMW and mechanical loading, regardless of the width of the repair welding

  9. Reliability assessment of underground pipelines under the combined effect of active corrosion and residual stress

    International Nuclear Information System (INIS)

    Amirat, A.; Mohamed-Chateauneuf, A.; Chaoui, K.

    2006-01-01

    Lifetime management of underground pipelines is mandatory for safe hydrocarbon transmission and distribution systems. Reliability analysis is recognized as a powerful decision-making tool for risk-based design and maintenance. Both the residual stresses generated during the manufacturing process and in-service corrosion reduce the ability to resist internal and external loading. In this study, the residual stress distribution in large diameter pipes has been characterized experimentally in order to be coupled with the corrosion model. During the pipe lifetime, residual stress relaxation occurs due to the loss of pipe thickness as material layers are consumed by corrosion. The reliability-based assessment of residual stress effects is applied to underground pipelines under a roadway, with and without active corrosion. It has been found that the residual stress greatly increases the failure probability, especially in the early stage of the pipe lifetime

  10. Experimental stress analysis for determination of residual stresses and integrity monitoring of components and systems

    International Nuclear Information System (INIS)

    1993-01-01

    For an analysis of the safety-related significance of residual stresses, mechanical, magnetic as well as ultrasonic and diffraction methods can be applied as testing methods. The results of an interlaboratory test concerning the experimental determination of residual stresses in a railway track are included. Further, questions are analyzed concerning the in-service inspections of components and systems with regard to their operational safety and life. Measurement methods are explained by examples from power plant engineering, nuclear power plant engineering, construction and traffic engineering as well as aeronautics. (DG) [de

  11. Fatigue life evaluation based on welding residual stress relaxation and notch strain approach for cruciform welded joint

    International Nuclear Information System (INIS)

    Han, Jeong Woo; Han, Seung Ho; Shin, Byung Chun; Kim, Jae Hoon

    2003-01-01

    The fatigue strength of welded joint is influenced by the welding residual stress which is relaxed depending on local stress distributed in vicinity of stress raisers, eg. under cut, overlap and blow hole. To evaluate its fatigue life the geometry of the stress raisers and the welding residual stress should be taken into account. The several methods based on notch strain approach have been proposed in order to consider the two factors above mentioned. These methods, however, have shown considerable differences between analytical and experimental results. It is due to the fact that the amount of the relaxed welding residual stress evaluated by the cyclic stress-strain relationship do not correspond with that occurred in reality. In this paper the residual stress relaxation model based on experimental results was used in order to reduce the discrepancy of the estimated amount of the relaxed welding residual stress. Under an assumption of the superimposition of the relaxed welding residual stress and the local stress, a modified notch strain approach was proposed and verified to the cruciform welded joint

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

    Science.gov (United States)

    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.

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

    Science.gov (United States)

    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.

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

    Science.gov (United States)

    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. Estimation of residual stress distribution for pressurizer nozzle of Kori nuclear power plant considering safe end

    Energy Technology Data Exchange (ETDEWEB)

    Song, Tae Kwang; Bae, Hong Yeol; Chun, Yun Bae; Oh, Chang Young; Kim, Yun Jae [Korea University, Seoul (Korea, Republic of); Lee, Kyoung Soo; Park, Chi Yong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of)

    2008-08-15

    In nuclear power plants, ferritic low alloy steel nozzle was connected with austenitic stainless steel piping system through alloy 82/182 butt weld. Accurate estimation of residual stress for weldment is important in the sense that alloy 82/182 is susceptible to stress corrosion cracking. There are many results which predict residual stress distribution for alloy 82/182 weld between nozzle and pipe. However, nozzle and piping system usually connected through safe end which has short length. In this paper, residual stress distribution for pressurizer nozzle of Kori nuclear power plant was predicted using FE analysis, which considered safe end. As a result, existing residual stress profile was redistributed and residual stress of inner surface was decreased specially. It means that safe end should be considered to reduce conservatism when estimating the piping system.

  16. Dependence of the frequency spectrum of small amplitude vibrations superimposed on finite deformations of a nonlinear, cylindrical elastic body on residual stress

    KAUST Repository

    Gorb, Yuliya

    2010-11-01

    We model and analyze the response of nonlinear, residually stressed elastic bodies subjected to small amplitude vibrations superimposed upon large deformations. The problem derives from modeling the use of intravascular ultrasound (IVUS) imaging to interrogate atherosclerotic plaques in vivo in large arteries. The goal of this investigation is twofold: (i) introduce a modeling framework for residual stress that unlike traditional Fung type classical opening angle models may be used for a diseased artery, and (ii) investigate the sensitivity of the spectra of small amplitude high frequency time harmonic vibrations superimposed on a large deformation to the details of the residual stress stored in arteries through a numerical simulation using physiologic parameter values under both low and high blood pressure loadings. The modeling framework also points the way towards an inverse problem using IVUS techniques to estimate residual stress in healthy and diseased arteries. © 2010 Elsevier Ltd. All rights reserved.

  17. Residual stress evolution regularity in thermal barrier coatings under thermal shock loading

    Directory of Open Access Journals (Sweden)

    Ximin Chen

    2014-01-01

    Full Text Available Residual stress evolution regularity in thermal barrier ceramic coatings (TBCs under different cycles of thermal shock loading of 1100°C was investigated by the microscopic digital image correlation (DIC and micro-Raman spectroscopy, respectively. The obtained results showed that, as the cycle number of the thermal shock loading increases, the evolution of the residual stress undergoes three distinct stages: a sharp increase, a gradual change, and a reduction. The extension stress near the TBC surface is fast transformed to compressive one through just one thermal cycle. After different thermal shock cycles with peak temperature of 1100°C, phase transformation in TBC does not happen, whereas the generation, development, evolution of the thermally grown oxide (TGO layer and micro-cracks are the main reasons causing the evolution regularity of the residual stress.

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

    Science.gov (United States)

    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.

  19. Evaluation of residual stress on pipe welded joints using laser interferometry

    Energy Technology Data Exchange (ETDEWEB)

    Chang, Ho Seob; Na, Man Gyun; Kim, Koung Suk [Chosun University, Gwangju (Korea, Republic of)

    2014-02-15

    Residual stresses that occur during the welding process, are the main cause of failure and defects in welded structures. This paper, presents the use of an electronic processing laser speckle interferometer to measure the residual stress of a welded pipe for a nuclear power plant. A tensile testing machine was used to evaluate a welded pipe that failed in compression. The inform plane deformation and modulus of elasticity of the base metal and welds were measured using an interferometer. Varying the load on the welded pipe had a larger effect on the deformation of the base metal the other properties of the base metal and welds. The elastic moduli of the base metal and weld of the welded pipe were 202.46 and 212.14 GPa, respectively, the residual stress was measured to be 6.29 MPa.

  20. Experimental determination of residual stress by neutron diffraction in a boiling water reactor core shroud

    International Nuclear Information System (INIS)

    Payzant, A.; Spooner, S.; Zhu, Xiaojing; Hubbard, C.R.

    1996-01-01

    Residual strains in a 51 mm (2-inch) thick 304L stainless steel plate have been measured by neutron diffraction and interpreted in terms of residual stress. The plate, measuring (300 mm) in area, was removed from a 6m (20-ft.) diameter unirradiated boiling water reactor core shroud, and included a multiple-pass horizontal weld which joined two of the cylindrical shells which comprise the core shroud. Residual stress mapping was undertaken in the heat affected zone, concentrating on the outside half of the plate thickness. Variations in residual stresses with location appeared consistent with trends expected from finite element calculations, considering that a large fraction of the residual hoop stress was released upon removal of the plate from the core shroud cylinder

  1. The influence of punching process on residual stress and magnetic domain structure of non-oriented silicon steel

    International Nuclear Information System (INIS)

    Cao, Hongzhi; Hao, Linpo; Yi, Jingwen; Zhang, Xianglin; Luo, Zhonghan; Chen, Shenglin; Li, Rongfeng

    2016-01-01

    The main purpose of this paper is to investigate the influence of punching process on residual stress and magnetic domain structure. The residual stress in non-oriented silicon steel after punching process was measured by nanoindentation. The maximum depth was kept constant as 300 nm during nanoindentation. The material around indentation region exhibited no significant pile-up deformation. The calculation of residual stress was based on the Suresh theoretical model. Our experimental results show that residual compressive stress was generated around the sheared edge after punching. The width of residual stress affected zone by punching was around 0.4–0.5 mm. After annealing treatment, the residual stress was significantly decreased. Magnetic domain structure was observed according to the Bitter method. The un-annealed sample exhibited complicated domain patterns, and the widths of the magnetic domains varied between 3 µm and 8 µm. Most of the domain patterns of the annealed sample were 180°-domains and 90°-domains, and the widths of the domains decreased to 1–3 µm. - Highlights: • The residual stress distribution on sheared edge was measured. • The residual compressive stress was generated around the sheared edge. • The width of residual stress affected zone was about 0.4–0.5 mm. • The shape and width of the domain structure would be changed by annealing.

  2. Residual Stresses in SAVY 4000 and Hagan Container Bodies

    Energy Technology Data Exchange (ETDEWEB)

    Stroud, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Hill, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Tokash, Justin Charles [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Forsyth, Robert Thomas [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Hyer, Holden Christopher [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-11-02

    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 showed 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.

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

    Science.gov (United States)

    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.

  4. Standard test method for determining the effective elastic parameter for X-ray diffraction measurements of residual stress

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    1998-01-01

    1.1 This test method covers a procedure for experimentally determining the effective elastic parameter, Eeff, for the evaluation of residual and applied stresses by X-ray diffraction techniques. The effective elastic parameter relates macroscopic stress to the strain measured in a particular crystallographic direction in polycrystalline samples. Eeff should not be confused with E, the modulus of elasticity. Rather, it is nominally equivalent to E/(1 + ν) for the particular crystallographic direction, where ν is Poisson's ratio. The effective elastic parameter is influenced by elastic anisotropy and preferred orientation of the sample material. 1.2 This test method is applicable to all X-ray diffraction instruments intended for measurements of macroscopic residual stress that use measurements of the positions of the diffraction peaks in the high back-reflection region to determine changes in lattice spacing. 1.3 This test method is applicable to all X-ray diffraction techniques for residual stress measurem...

  5. Fatique crack propagation in bimetallic welds influence of residual stresses and metallurgical look

    International Nuclear Information System (INIS)

    Zahouane, A.I.

    1988-06-01

    Generally, in nuclear power plants, many components made of austenitic stainless steels are very often replaced by low alloyed steels cladded with stainless steels, mainly for economical reasons. Due to cracks existing at the limit of the two kinds of steel, it is interesting to try to understand how they appear. Residual stresses are generally identified as one of the factors which act to produce these cracks. Measurements of such residual stresses have been performed, using the hole drilling method (drilling of a hole at the center of a gauge roset stuck at the surface of the material). Owing to the obtained results, it is possible to explain the decrease in the crack propagation rate observed, on fatigue crack growth test performed on specimens taken in the transition ferritic/austenitic zone. The stress intensity factor due to the residual stresses is valued by weight function method. It is possible to explain qualitatively the phenomena observed under cyclic loading when using the obtained value of this stress intensity factor. A more quantitative approach based on the use of an efficient stress intensity factor, allow to better describe the effect of residual stresses on the fatigue crack propagation in bimetallic welds [fr

  6. Characteristics of the Residual Stress tensor when filter width is larger than the Ozmidov scale

    Science.gov (United States)

    de Bragança Alves, Felipe Augusto; de Bruyn Kops, Stephen

    2017-11-01

    In stratified turbulence, the residual stress tensor is statistically anisotropic unless the smallest resolved length scale is smaller than the Ozmidov scale and the buoyancy Reynolds number is sufficiently high for there to exist a range of scales that is statistically isotropic. We present approximations to the residual stress tensor that are derived analytically. These approximations are evaluated by filtering data from direct numerical simulations of homogeneous stratified turbulence, with unity Prandtl number, resolved on up to 8192 × 8192 × 4096 grid points along with an isotropic homogeneous case resolved on 81923 grid points. It is found that the best possible scaling of the strain rate tensor yields a residual stress tensor (RST) that is less well statistically aligned with the exact RST than a randomly generated tensor. It is also found that, while a scaling of the strain rate tensor can dissipate the right amount of energy, it produces incorrect anisotropic dissipation, removing energy from the wrong components of the velocity vector. We find that a combination of the strain rate tensor and a tensor related to energy redistribution caused by a Newtonian fluid viscous stress yields an excellent tensorial basis for modelling the RST.

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

    Science.gov (United States)

    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.

  8. X-ray diffraction and measurement of residual stresses

    International Nuclear Information System (INIS)

    Maeder, G.; Lebrun, J.L.; Corcaud, L.

    1977-01-01

    X-ray diffraction technique is a non destructive method for measuring the residual stresses in mechanical parts. This method, called sin 2 PSI method is investigated. It is applied to the measurement of elastic constants in different directions of crystals of Zr alloy (Zircaloy 4) and Ti alloy (TA6V). Stresses in TA6V sheets welded by TIG and electron beam processes are also studied [fr

  9. Different finite element techniques to predict welding residual stresses in aluminum alloy plates

    International Nuclear Information System (INIS)

    Moein, Hadi; Sattari-Far, Iradj

    2014-01-01

    This study is a 3D thermomechanical finite element (FE) analysis of a single-pass and butt-welded work-hardened aluminum (Al) 5456 plates. It aims to validate the use of FE welding simulations to predict residual stress states in assessing the integrity of welded components. The predicted final residual stresses in the plate from the FE simulations are verified through comparison with experimental measurements. Three techniques are used to simulate the welding process. In the first two approaches, welding deposition is applied by using element birth and interaction techniques. In the third approach, the entire weld zone is simultaneously deposited. Results show a value at approximately the yield strength for longitudinal residual stresses of the welded center of the butt-welded Al alloy plates with a thickness of 2 mm. Considering the application of a comprehensive heat source, along with heat loss modeling and the temperature dependent properties of the material, the approach without deposition predicts a reasonable distribution of residual stresses. However, the element birth and interaction techniques, compared with the no-deposit technique, provide more accurate results in calculating residual stresses. Furthermore, the element interaction technique, compared with the element birth technique, exhibits higher efficiency and flexibility in modeling the deposition of welded metals as well as less modeling cost.

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

    Science.gov (United States)

    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.

  11. Eddy Current Nondestructive Residual Stress Assessment in Shot-Peened Nickel-Base Superalloys

    International Nuclear Information System (INIS)

    Blodgett, M.P.; Yu, F.; Nagy, P.B.

    2005-01-01

    Shot peening and other mechanical surface enhancement methods improve the fatigue resistance and foreign-object damage tolerance of metallic components by introducing beneficial near-surface compressive residual stresses and hardening the surface. However, the fatigue life improvement gained via surface enhancement is not explicitly accounted for in current engine component life prediction models because of the lack of accurate and reliable nondestructive methods that could verify the presence of compressive near-surface residual stresses in shot-peened hardware. In light of its frequency-dependent penetration depth, the measurement of eddy current conductivity has been suggested as a possible means to allow the nondestructive evaluation of subsurface residual stresses in surface-treated components. This technique is based on the so-called piezoresistivity effect, i.e., the stress-dependence of electrical resistivity. We found that, in contrast with most other materials, surface-treated nickel-base superalloys exhibit an apparent increase in electrical conductivity at increasing inspection frequencies, i.e., at decreasing penetration depths. Experimental results are presented to illustrate that the excess frequency-dependent apparent eddy current conductivity of shot-peened nickel-base superalloys can be used to estimate the absolute level and penetration depth of the compressive residual stress layer both before and after partial thermal relaxation

  12. The effect of tensioning and sectioning on residual stresses in aluminium AA7749 friction stir welds

    International Nuclear Information System (INIS)

    Altenkirch, J.; Steuwer, A.; Peel, M.; Richards, D.G.; Withers, P.J.

    2008-01-01

    Using synchrotron X-ray diffraction the residual stress distribution has been measured in a series of AA7449-W51 aluminium friction stir welds that had been tensioned to different loads during welding. By modifying the stress accumulation path, the application of a tensioning stress has reduced the tensile magnitude of the final residual weld stresses. In the present case the residual stresses were minimised when the applied load is ∼35% of the room temperature yield stress of the parent material. Subsequent sectioning of the weld into shorter test lengths, as might be necessary for weld testing, resulted in a progressive and significant relaxation of the residual stress field. The effect of tensioning on the weld component distortion also has been investigated

  13. Numerical Analysis of Joule Heating Behavior and Residual Compressive Stress around Crack Tip under High Electric Load

    Directory of Open Access Journals (Sweden)

    Thomas Jin-Chee Liu

    2017-01-01

    Full Text Available This paper discusses the Joule heating effect and residual compressive stress near the crack tip under the electro-thermo-structural coupling state. For the crack tip field, the compressive condition is important for retarding or stopping the crack growth.

  14. Effect of preemptive weld overlay on residual stress of repaired weldment in surge nozzle

    Energy Technology Data Exchange (ETDEWEB)

    Oh, Chang Young; Song, Tae Kwang; Bae, Hong Yeol; Chun, Yun Bae; Kim, Yun Jae [Korea Univ., Seoul (Korea, Republic of); Lee, Kyoung Soo; Park, Chi Yong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of)

    2008-07-01

    In the welding process, weldments usually include repair weld during the manufacturing process. Repair welds is supposed to cause strong tensile residual stress. Moreover weldments, usually made by Alloy 82/182, is susceptible to PWSCC. Therefore, mitigation of welding residual stress in weldments is important for reliable operating. PWOL is one of the methods for mitigation and verified for over twenty years. In this paper, residual stress distribution of repaired weldments and the effect of PWOL on mitigation is examined for surge nozzle.

  15. Residual Stress Induced by Nitriding and Nitrocarburizing

    DEFF Research Database (Denmark)

    Somers, Marcel A.J.

    2005-01-01

    The present chapter is devoted to the various mechanisms involved in the buildup and relief of residual stress in nitrided and nitrocarburized cases. The work presented is an overview of model studies on iron and iron-based alloys. Subdivision is made between the compound (or white) layer......, developing at the surfce and consisting of iron-based (carbo)nitrides, and the diffusion zone underneath, consisting of iron and alloying element nitrides dispersed in af ferritic matrix. Microstructural features are related directly to the origins of stress buildup and stres relief....

  16. X-ray diffraction analysis of residual stresses in alumina-chromium composites and comparison with numerical simulations

    Energy Technology Data Exchange (ETDEWEB)

    Geandier, G.; Weisbecker, P.; Denis, S.; Mocellin, A. [L.S.G.2M., UMR, CNRS/INPL, Ecole des Mines de Nancy, Nancy (France); Hazotte, A. [L.S.G.2M., UMR, CNRS/INPL, Ecole des Mines de Nancy, Nancy (France); LETAM, UMR, CNRS/Metz Univ., ISGMP, Metz (France); Lebrun, J.L. [L.P.M.I., ENSAM Angers, Angers (France); Elkaim, E. [L.U.R.E., Centre Univ. Paris-Sud, Orsay (France)

    2002-07-01

    Residual stresses in alumina chromium composites have been determined using X ray synchrotron diffraction at LURE. Results show that non-negligible residual stresses exist in the composites. Mean residual stresses calculated by finite element show discrepancies with experimental values that are discussed in relation with experimental difficulties and calculation assumptions. (orig.)

  17. FEM simulation study on relationship of interfacial morphology and residual stress in TBCs

    Energy Technology Data Exchange (ETDEWEB)

    Liqiang Chen; Shengkai Gong; Huibin Xu [School of Materials Science and Engineering, Beihang Univ., Beijing, BJ (China)

    2005-07-01

    It is generally believed that the failure of TBCs is attributed to the spallation occurred in the ceramic coat. The spallation is closed linked with sinuate morphology factors, including its amplitude and period, at the TGO/bond coat interface. In this work, dependence of the residual stress distribution on the sinuate morphology in the TBCs has been studied by means of finite element method (FEM) simulation for isothermally annealed specimens. The simulation results indicated that the maximum value of residual stress existed inside the TGO layer. It was also found that the maximum residual stress occurred at different points, near the TGO/bond coat interface at the peak of the sinuate interface, while near the TGO/ceramic coat interface at the valley, respectively. And the maximum residual stress increased with increasing the ratio of the amplitude to period in the sine morphology, which has been proved by the thermal cycle experimental results. (orig.)

  18. Calculation of residual stresses by means of a 3D numerical weld simulation

    International Nuclear Information System (INIS)

    Nicak, Tomas; Huemmer, Matthias

    2008-01-01

    The numerical weld simulation has developed very fast in recent years. The problem complexity has increased from simple 2D models to full 3D models, which can describe the entire welding process more realistically. As recent research projects indicate, a quantitative assessment of the residual stresses by means of a 3D analysis is possible. The structure integrity can be assessed based on the weld simulation results superimposed with the operating load. Moreover, to support the qualification of welded components parametric studies for optimization of the residual stress distribution in the weld region can be performed. In this paper a full 3D numerical weld simulation for a man-hole drainage nozzle in a steam generator will be presented. The residual stresses are calculated by means of an uncoupled transient thermal and mechanical FE analysis. The paper will present a robust procedure allowing reasonable predictions of the residual stresses for complex structures in industrial practice. (authors)

  19. Residual stresses associated with the hydraulic expansion of steam generator tubing into tubesheets

    International Nuclear Information System (INIS)

    Middlebrooks, W.B.; Harrod, D.L.; Gold, R.E.

    1991-01-01

    Westinghouse has used three different processes for the full depth expansion of tubes into the tube sheets of recirculating nuclear steam generators: mechanical rolling, explosive expansion and hydraulic expansion. Each process aims at expanding tubes tightly to tube sheets, leaving the smallest possible secondary side crevice depth, and minimizing the residual stress in the expanded tubes, all for the purpose of mitigating the effect of corrosion phenomena. The hydraulic expansion process was qualified and has been implemented since 1978, and more than 1.1 million tube ends have been hydraulically expanded into production units. In this paper, the results of the recent analytical studies related to the residual stress in the expanded tubes are summarized. The method of hydraulic expansion is explained, and some important parameters are given. Finite element method, theoretical incremental analysis, tube sheet yielding and residual stress, contact pressure, sensitivity analysis and temperature effect in the central region of tube sheets, and the residual stress in the transition zone are described. (K.I.)

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

    Science.gov (United States)

    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.

  1. The influence of residual stresses on small through-clad cracks in pressure vessels

    International Nuclear Information System (INIS)

    deLorenzi, H.G.; Schumacher, B.I.

    1984-01-01

    The influence of cladding residual stresses on the crack driving force for shallow cracks in the wall of a nuclear pressure vessel is investigated. Thermo-elastic-plastic analyses were carried out on long axial through-clad and sub-clad flaws on the inside of the vessel. The depth of the flaws were one and three times the cladding thickness, respectively. An analysis of a semielliptical axial through-clad flaw was also performed. It was assumed that the residual stresses arise due to the difference in the thermal expansion between the cladding and the base material during the cool down from stress relieving temperature to room temperature and due to the subsequent proof test before the vessel is put into service. The variation of the crack tip opening displacement during these loadings and during a subsequent thermal shock on the inside wall is described. The analyses for the long axial flaws suggest that the crack driving force is smaller for this type of flaw if the residual stresses in the cladding are taken into account than if one assumes that the cladding has no residual stresses. However, the analysis of the semielliptical flaw shows significantly different results. Here the crack driving force is higher than when the residual stresses are not taken into account and is maximum in the cladding at or near the clad/base material interface. This suggests that the crack would propagate along the clad/base material interface before it would penetrate deeper into the wall. The elastic-plastic behavior found in the analyses show that the cladding and the residual stresses in the cladding should be taken into acocunt when evaluating the severity of shallow surface cracks on the inside of a nuclear pressure vessel

  2. Manufacturing inspection of electrical steels using Magnetic Barkhausen Noise: residual stress detection

    Energy Technology Data Exchange (ETDEWEB)

    Samimi, A.A., E-mail: 9aa8@queensu.ca [Queen' s Univ., Applied Magnetics Group, Kingston, Ontario (Canada); Krause, T.W. [Royal Military College of Canada, NDE Lab., Kingston, Ontario (Canada); Clapham, L. [Queen' s Univ., Applied Magnetics Group, Kingston, Ontario (Canada); Gallaugher, M.; Ding, Y.; Chromik, R. [McGill Univ., Dept. of Mining and Materials Engineering, Montreal, Quebec (Canada)

    2016-09-15

    Non-oriented Electrical Steel (NOES) is the magnetic core lamination material used for flux transfer in rotary machines. The presence of residual stress associated with material processing may be detrimental to magnetic domain structure refinement and as a result, magnetic performance of NOES. Therefore, manufacturing inspection of NOES that identifies the presence of residual stress could contribute to the production of more energy efficient cores. However, standard materials evaluation is limited to destructive and off-line techniques. The present work employed Magnetic Barkhausen Noise (MBN) for nondestructive identification of local residual stress associated with stages in material processing. Analysis of MBN from single strips of NOES demonstrated clear response to applied tensile stress, mechanical shearing, the presence of an insulating coating and punching. The results establish the potential of MBN as a nondestructive testing technology for quality control of electrical steels at various stages of manufacture. (author)

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

    Science.gov (United States)

    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

  4. Effects of filler wire on residual stress in electron beam welded QCr0.8 copper alloy to 304 stainless steel joints

    International Nuclear Information System (INIS)

    Zhang, Bing-Gang; Zhao, Jian; Li, Xiao-Peng; Chen, Guo-Qing

    2015-01-01

    The electron beam welding (EBW) of 304 stainless steel to QCr0.8 copper alloy with or without copper filler wire was studied in detail. The temperature fields and magnitude and distribution of stress fields in the joints during the welding process were numerically simulated using finite element method. The temperature cycles and residual stresses were also experimentally measured by thermometric and hole-drilling methods, respectively. The accuracy of the modeling procedure was verified by the good agreement between the calculated results and experimental data. The temperature distribution in the joint was found to be asymmetric along the center of weld. In particular, the temperature in the copper alloy plate is much higher than that in the 304 SS plate owing to the great difference in thermal conductivity between the two materials. The peak three-dimensional residual stresses all appeared at the interface between the copper and steel in the two different joints. Furthermore, the weld was subjected to tensile stress. The longitudinal residual stress, generally the most harmful to the integrity of the structure among the stress components in EBW with filler wire (EBFW), was 53 MPa lower than that of autogenous EBW (AEBW), and the through-thickness residual stress was 12 MPa lower. The transverse residual stress of EBFW was 44 MPa higher than that of AEBW. However, analysis of the von Mises stress showed that the EBFW process effectively reduced the extent of the high residual stress region in the weld location and the magnitude of the residual stresses in the copper side compared with those of the AEBW joint. - Highlights: • Copper and steel was welded by electron beam welding with copper filler wire. • The copper wire fed into gap can reduce the peak value of residual stress. • The peak value of longitudinal stress can be reduced 53 MPa by the filler wire. • The range of nov Mises stress in the weld could be reduced by the wire

  5. Residual stress measurement inside a dissimilar metal weld mock-up of the pressurizer safety and relief nozzle

    International Nuclear Information System (INIS)

    Campos, Wagner R.C.; Rabello, Emerson G.; Silva, Luiz L.; Mansur, Tanius R.; Martins, Ketsia S.

    2015-01-01

    Residual stresses are present in materials or structural component in the absence of external loads or changes in temperatures. The most common causes of residual stresses being present are the manufacturing or assembling processes. All manufacturing processes, such as casting, welding, machining, molding, heat treatment, among others, introduces residual stresses into the manufactured object. The residual stresses effects could be beneficial or detrimental, depending on its distribution related to the component or structure, its load service and if it is compressive or tensile. In this work, the residual strains and stresses inside a mock-up that simulates the safety and relief nozzle of Angra 1 Nuclear Power Plant pressurizer were studied. The current paper presents a blind hole-drilling method residual stress measurements both at the inner surface of dissimilar metal welds of dissimilar metal weld nozzle mock-up. (author)

  6. Residual stress measurement inside a dissimilar metal weld mock-up of the pressurizer safety and relief nozzle

    Energy Technology Data Exchange (ETDEWEB)

    Campos, Wagner R.C.; Rabello, Emerson G.; Silva, Luiz L.; Mansur, Tanius R., E-mail: wrcc@cdtn.br, E-mail: egr@cdtn.br, E-mail: silvall@cdtn.br, E-mail: tanius@cdtn.br [Centro de Desenvolvimento da Tecnologia Nuclear (CDTN/CNEN-MG), Belo Horizonte (Brazil). Servico de Integridade Estrutural; Martins, Ketsia S., E-mail: ketshinoda@hotmail.com [Universidade Federal de Minas Gerais (UFMG), Nelo Horizonte (Brazil). Departamento de Engenharia Metalurgica

    2015-07-01

    Residual stresses are present in materials or structural component in the absence of external loads or changes in temperatures. The most common causes of residual stresses being present are the manufacturing or assembling processes. All manufacturing processes, such as casting, welding, machining, molding, heat treatment, among others, introduces residual stresses into the manufactured object. The residual stresses effects could be beneficial or detrimental, depending on its distribution related to the component or structure, its load service and if it is compressive or tensile. In this work, the residual strains and stresses inside a mock-up that simulates the safety and relief nozzle of Angra 1 Nuclear Power Plant pressurizer were studied. The current paper presents a blind hole-drilling method residual stress measurements both at the inner surface of dissimilar metal welds of dissimilar metal weld nozzle mock-up. (author)

  7. Analysis of shot-peening and residual stress relaxation in the nickel-based superalloy RR1000

    International Nuclear Information System (INIS)

    Foss, B.J.; Gray, S.; Hardy, M.C.; Stekovic, S.; McPhail, D.S.; Shollock, B.A.

    2013-01-01

    This work assesses the residual stress relaxation of the nickel-based alloy RR1000 due to thermal exposure and dwell-fatigue loading. A number of different characterization methods, including X-ray residual stress analysis, electron back-scattered diffraction, microhardness testing and focused ion beam secondary electron imaging, contributed to a detailed study of the shot-peened region. Thermal exposure at 700 °C resulted in a large reduction in the residual stresses and work-hardening effects in the alloy, but the subsurface remained in a beneficial compressive state. Oxidizing environments caused recrystallization in the near surface, but did not affect the residual stress-relaxation behaviour. Dwell-fatigue loading caused the residual stresses to return to approximately zero at nearly all depths. This work forms part of an ongoing investigation to determine the effects of shot-peening in this alloy with the motivation to improve the fatigue and oxidation resistance at 700 °C

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

    Science.gov (United States)

    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.

  9. Microscopic residual stress evolution during deformation process of an Fe---Mn---Si---Cr shape memory alloy investigated using white X-ray microbeam diffraction

    International Nuclear Information System (INIS)

    Kwon, E.P.; Sato, S.; Fujieda, S.; Shinoda, K.; Kajiwara, K.; Sato, M.; Suzuki, S.

    2013-01-01

    Microscopic residual stress evolution in different austenite (γ) grains during shape memory process in an Fe---Mn---Si---Cr alloy was investigated using the white X-ray microbeam diffraction technique. The use of high-energy white X-ray microbeam with small beam size allowed us to measure the microscopic residual stress in coarse γ grains with specific orientation. After tensile deformation large compressive residual stress was evolved in γ grains due to the formation of stress-induced ε martensite, but upon recovery heating it almost disappeared as a result of reverse transformation of martensite. The magnitude of compressive residual stress was higher in grains with orientations close to 〈144〉 and 〈233〉 orientations than in a grain with near 〈001〉 orientation. Analysis of the microstructure of each grain using electron backscattering diffraction suggested that the difference in the magnitude of compressive residual stress could be attributed to different martensitic transformation characteristics in the grains

  10. Proposed residual stress model for roller bent wide flange sections

    NARCIS (Netherlands)

    Spoorenberg, R.C.; Snijder, H.H.; Hoenderkamp, J.C.D.

    2011-01-01

    The manufacturing process of structural wide flange steel sections introduces residual stresses in the material. These stresses due to hot-rolling or welding influence the inelastic buckling response of structural steel members and need to be taken into account in the design. Based on experimental

  11. Modeling of residual stress mitigation in austenitic stainless steel pipe girth weldment

    International Nuclear Information System (INIS)

    Li, M.; Atteridge, D.G.; Anderson, W.E.; West, S.L.

    1994-01-01

    This study provides numerical procedures to model 40-cm-diameter, schedule 40, Type 304L stainless steel pipe girth welding and a newly proposed post-weld treatment. The treatment can be used to accomplish the goal of imparting compressive residual stresses at the inner surface of a pipe girth weldment to prevent/retard the intergranular stress corrosion cracking (IGSCC) of the piping system in nuclear reactors. This new post-weld treatment for mitigating residual stresses is cooling stress improvement (CSI). The concept of CSI is to establish and maintain a certain temperature gradient across the pipe wall thickness to change the final stress state. Thus, this process involves sub-zero low temperature cooling of the inner pipe surface of a completed girth weldment, while simultaneously keeping the outer pipe surface at a slightly elevated temperature with the help of a certain heating method. Analyses to obtain quantitative results on pipe girth welding and CSI by using a thermo-elastic-plastic finite element model are described in this paper. Results demonstrate the potential effectiveness of CSI for introducing compressive residual stresses to prevent/retard IGSCC. Because of the symmetric nature of CSI, it shows great potential for industrial application

  12. Investigation of residual stresses in thick-walled vessels with combination of autofrettage and wire-winding

    International Nuclear Information System (INIS)

    Sedighi, M.; Jabbari, A.H.

    2013-01-01

    Wire-winding and autofrettage processes can be used to introduce beneficial residual stress in the cylinder of thick-walled pressure vessels. In both techniques, internal residual compressive stress will increase internal pressure capacity, improve fatigue life and reduce fatigue crack initiation. The purpose of this paper is to analyze the effects of wire-winding on an autofrettaged thick-walled vessel. Direct method which is a modified Variable Material Properties (VMP) method has been used in order to calculate residual stresses in an autofrettaged vessel. Since wire-winding is done after autofrettage process, the tangent and/or Young's modulus could be changed. For this reason, a new wire-winding method based on Direct Method is introduced. The obtained results for wire-wound autofrettaged vessels are validated by finite element method. The results show that by using this approach, the residual hoop stresses in a wire-wound autofrettaged vessel have a more desirable distribution in the cylinder. -- Highlights: • Combination of autofrettage and wire-winding in pressure vessels has been presented. • A new method based on Direct method is presented for wire-winding process. • Residual hoop stresses are compared in vessels cylinders for different cases. • The residual hoop stress has a more desirable stress distribution. • The benefits of the combined vessel are highlighted in comparison with single cases

  13. Effects of residual stress on fatigue strength of small diameter welded pipe joint

    International Nuclear Information System (INIS)

    Yamashita, Tetsuo; Hattori, Takahiro; Nomoto, Toshiharu; Iida, Kunihiro; Sato, Masanobu

    1996-01-01

    A power plant consists of many welded components, therefore, it is essential in establishing the reliability of the power plant to maintain the reliability of all welded components. The fatigue failure caused by mechanical vibrations of small diameter welded joints, which is represented by socket welded joints, is one of the major causes of trouble for the welded parts of the power plant. Here, bending fatigue tests were conducted to investigate the fatigue strength of small diameter socket welded pipe joints. In the most cases of large diameter socket joints, a fatigue crack started from the root of the fillet weld though the stress amplitude at the root was smaller than that at the toe of fillet weld. Additionally, the fatigue strength was affected by the weld bead sequence. The residual stress was considered to be one of the important parameters governing fatigue strength, therefore, its effects were investigated. In several types of pipe joints, the local stress and residual stress distributions were calculated by finite element analysis. The residual stresses were compressive at the toe and tensile at the root of the socket welded joints. Based on these results, the effects of residual stresses on the fatigue strength are discussed for small diameter welded pipe joints in the present work

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

    Science.gov (United States)

    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.

  15. Validation of Weld Residual Stress Modeling in the NRC International Round Robin Study

    International Nuclear Information System (INIS)

    Mullins, Jonathan; Gunnars, Jens

    2013-01-01

    Weld residual stresses (WRS) have a large influence on the behavior of cracks growing under normal operation loads and on the leakage flow from a through-wall crack. Accurate prediction on weld residual stresses is important to make proper decisions when cracks in weld joints are detected. During the latest years, there has been a strong development in both analytical procedures to numerically determine WRS and experimental measurements of WRS. The USNRC (United States Nuclear Regulatory Commission) has formed a program for validation of WRS predictions through comparison of numerically calculated residual stress fields in dissimilar welds measured by different methods. The present report describes the results of the project with special focus on the contribution from Inspecta Technology. Objectives: The principal objective of the project is to compare different WRS predictions for a dissimilar pipe weld with careful measurements on a mock-up weld. The results of the project will make it possible to make recommendations on computational procedures for WRS in dissimilar metal welds. Results: It is concluded that numerical analysis of weld residual stresses using the finite element method is very useful for the estimation of weld residual stresses in complex geometries and dissimilar metal welds. The validation study increases the understanding of uncertainties associated with different modeling approaches and helps to identify the most sensitive parameters

  16. Residual stresses in surface induction hardening of steels: Comparison between experiment and simulation

    International Nuclear Information System (INIS)

    Coupard, Dominique; Palin-luc, Thierry; Bristiel, Philippe; Ji, Vincent; Dumas, Christian

    2008-01-01

    Deep induction hardening has been performed on two batches of smooth cylindrical specimens with a hardening depth respectively around 2 mm and 3 mm. The distributions of axial and circumferential residual stresses are analysed for the two specimen batches by X-ray diffraction technique. The radial normal stress field is estimated through the use of the well known Moore and Evans correction. Finally, the experimental residual stresses are compared with those obtained from a multiphysic finite element modelling of the whole induction treatment process, including electromagnetic, thermal, metallurgical and mechanical phenomena. The simulated residual stress field is in good agreement with X-ray analysis especially at depths lower than one-tenth the specimen diameter. At deeper depths, a correction of the experimental X-ray analysis has been done to obtain realistic values

  17. Coping with residual stresses in the integrity assessment of an as-welded repair

    International Nuclear Information System (INIS)

    Knee, N.

    1989-11-01

    One of a series of large scale tests on pressure vessels is described, in which a defect was deliberately introduced into an as-welded (i.e. not stress relieved) repair weld. The behaviour of the vessel during pressurization to failure was carefully monitored and the actual performance compared with theoretical predictions. The influence of residual welding stresses on ductile crack growth from pre-existing defects is discussed in the light of the results of this test and of previous tests in the series. The tests have confirmed that residual stresses can exert a significant effect on the growth of fatigue cracks. However, in tests for which the failure mechanism is predominantly controlled by collapse of the remaining ligament, the development of plasticity during pressurization to failure will tend to remove any local residual stresses. (author)

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

    Science.gov (United States)

    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.

  19. Accounting for the residual stress effects on the creep deformation of channel tubes

    International Nuclear Information System (INIS)

    Knizhnikov, Yu.N.; Platonov, P.A.; Ul'yanov, A.I.

    1985-01-01

    The effect of the first kind residual stresses arising in the walls of the zirconium base alloy fules in the process of fabrication on the RBMK type reactor channel tube creep is investigated. Models for calculation of the reactor component creep with account for the relaxation of residual stresses distributed by the wall thickness as well as the radiation and temperature fields are developed. On the basis of the analysis of the data obtained it is concluded that the effect of the residual stresses on the RBMK channel tube deformation for a long-term operation is negligible. But for the short-term fests the results can be noticeably distorted by this factor. The role of internal stresses can also manifest when determining the deformation of radiation elongation of the zirconium base alloy samples

  20. Numerical weld modeling - a method for calculating weld-induced residual stresses

    International Nuclear Information System (INIS)

    Fricke, S.; Keim, E.; Schmidt, J.

    2001-01-01

    In the past, weld-induced residual stresses caused damage to numerous (power) plant parts, components and systems (Erve, M., Wesseling, U., Kilian, R., Hardt, R., Bruemmer, G., Maier, V., Ilg, U., 1994. Cracking in Stabilized Austenitic Stainless Steel Piping of German Boiling Water Reactors - Characteristic Features and Root Causes. 20. MPA-Seminar 1994, vol. 2, paper 29, pp.29.1-29.21). In the case of BWR nuclear power plants, this damage can be caused by the mechanism of intergranular stress corrosion cracking in austenitic piping or the core shroud in the reactor pressure vessel and is triggered chiefly by weld-induced residual stresses. One solution of this problem that has been used in the past involves experimental measurements of residual stresses in conjunction with weld optimization testing. However, the experimental analysis of all relevant parameters is an extremely tedious process. Numerical simulation using the finite element method (FEM) not only supplements this method but, in view of modern computer capacities, is also an equally valid alternative in its own right. This paper will demonstrate that the technique developed for numerical simulation of the welding process has not only been properly verified and validated on austenitic pipe welds, but that it also permits making selective statements on improvements to the welding process. For instance, numerical simulation can provide information on the starting point of welding for every weld bead, the effect of interpass cooling as far as a possible sensitization of the heat affected zone (HAZ) is concerned, the effect of gap width on the resultant weld residual stresses, or the effect of the 'last pass heat sink welding' (welding of the final passes while simultaneously cooling the inner surface with water) producing compressive stresses in the root area of a circumferential weld in an austenitic pipe. The computer program FERESA (finite element residual stress analysis) was based on a commercially

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

    International Nuclear Information System (INIS)

    Grassia, Luigi; D'Amore, Alberto

    2010-01-01

    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 reactive 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.

  2. Prediction of residual stress distribution in multi-stacked thin film by curvature measurement and iterative FEA

    International Nuclear Information System (INIS)

    Choi, Hyeon Chang; Park, Jun Hyub

    2005-01-01

    In this study, residual stress distribution in multi-stacked film by MEMS (Micro-Electro Mechanical System) process is predicted using Finite Element Method (FEM). We develop a finite element program for REsidual Stress Analysis (RESA) in multi-stacked film. The RESA predicts the distribution of residual stress field in multi-stacked film. Curvatures of multi-stacked film and single layers which consist of the multi-stacked film are used as the input to the RESA. To measure those curvatures is easier than to measure a distribution of residual stress. To verify the RESA, mean stresses and stress gradients of single and multilayers are measured. The mean stresses are calculated from curvatures of deposited wafer by using Stoney's equation. The stress gradients are calculated from the vertical deflection at the end of cantilever beam. To measure the mean stress of each layer in multi-stacked film, we measure the curvature of wafer with the film after etching layer by layer in multi-stacked film

  3. Experimental analysis of residual stresses in pre-straightened SAE 1045 steel

    Energy Technology Data Exchange (ETDEWEB)

    Diehl, Carla Adriana Theis Soares; Rocha, Alexandre da Silva, E-mail: carla.adriana@ufrgs.br [Universidade Federal do Rio Grande do Sul (UFRGS), Porto Alegre, RS (Brazil). Laboratorio de Formacao de Metais; Epp, Jérémy; Zoch, Hans-Werner [Stiftung Institut für Werkstofftechnik IWT, University of Bremen (Germany)

    2017-11-15

    This paper aims at analyzing the effects of the roller pre-straightening of wire-rods on residual stress distributions in SAE 1045 steel bars. The combined drawing process is used in industrial production of bars in order to obtain a good surface quality and improved mechanical properties complying with specifications of the final products. In this process, prior to the drawing step, a roller straightening of the steel wire-rod is essential, because it provides the minimum straightness necessary for drawing. Metallographic analysis and hardness test were done for selected samples after different processing steps. Also, residual stress analysis of pre-straightened wire-rods by X-ray diffraction and neutron diffraction were carried out. The hardness tests show higher values near the surface and lower in the center of the wire-rod. Besides, the residual stresses results show a big inhomogeneity from one peripheral position to another and also in the evaluated cross section. (author)

  4. Experimental analysis of residual stresses in pre-straightened SAE 1045 steel

    International Nuclear Information System (INIS)

    Diehl, Carla Adriana Theis Soares; Rocha, Alexandre da Silva

    2017-01-01

    This paper aims at analyzing the effects of the roller pre-straightening of wire-rods on residual stress distributions in SAE 1045 steel bars. The combined drawing process is used in industrial production of bars in order to obtain a good surface quality and improved mechanical properties complying with specifications of the final products. In this process, prior to the drawing step, a roller straightening of the steel wire-rod is essential, because it provides the minimum straightness necessary for drawing. Metallographic analysis and hardness test were done for selected samples after different processing steps. Also, residual stress analysis of pre-straightened wire-rods by X-ray diffraction and neutron diffraction were carried out. The hardness tests show higher values near the surface and lower in the center of the wire-rod. Besides, the residual stresses results show a big inhomogeneity from one peripheral position to another and also in the evaluated cross section. (author)

  5. Predictions and measurements of residual stress in repair welds in plates

    Energy Technology Data Exchange (ETDEWEB)

    Brown, T.B. [Mitsui Babcock Energy Limited, Technology and Engineering, Porterfield Road, Renfrew, PA4 8DJ, Scotland (United Kingdom)]. E-mail: bbrown@mitsuibabcock.com; Dauda, T.A. [Mitsui Babcock Energy Limited, Technology and Engineering, Porterfield Road, Renfrew, PA4 8DJ, Scotland (United Kingdom); Truman, C.E. [Department of Mechanical Engineering, University of Bristol, Bristol BS8 1TR, England (United Kingdom); Smith, D.J. [Department of Mechanical Engineering, University of Bristol, Bristol BS8 1TR (United Kingdom); Memhard, D. [Fraunhofer-Institut fuer Werkstoffmechanik, Freiburg (Germany); Pfeiffer, W. [Fraunhofer-Institut fuer Werkstoffmechanik, Freiburg (Germany)

    2006-11-15

    This paper presents the work, from the European Union FP-5 project ELIXIR, on a series of rectangular repair welds in P275 and S690 steels to validate the numerical modelling techniques used in the determination of the residual stresses generated during the repair process. The plates were 1,000 mm by 800 mm with thicknesses of 50 and 100 mm. The repair welds were 50%, 75% and 100% through the plate thickness. The repair welds were modelled using the finite element method to make predictions of the as-welded residual stress distributions. These predictions were compared with surface-strain measurements made on the parent plates during welding and found to be in good agreement. Through-thickness residual stress measurements were obtained from the test plates through, and local to, the weld repairs using the deep hole drilling technique. Comparisons between the measurements and the finite element predictions generally showed good agreement, thus providing confidence in the method.

  6. Predictions and measurements of residual stress in repair welds in plates

    International Nuclear Information System (INIS)

    Brown, T.B.; Dauda, T.A.; Truman, C.E.; Smith, D.J.; Memhard, D.; Pfeiffer, W.

    2006-01-01

    This paper presents the work, from the European Union FP-5 project ELIXIR, on a series of rectangular repair welds in P275 and S690 steels to validate the numerical modelling techniques used in the determination of the residual stresses generated during the repair process. The plates were 1,000 mm by 800 mm with thicknesses of 50 and 100 mm. The repair welds were 50%, 75% and 100% through the plate thickness. The repair welds were modelled using the finite element method to make predictions of the as-welded residual stress distributions. These predictions were compared with surface-strain measurements made on the parent plates during welding and found to be in good agreement. Through-thickness residual stress measurements were obtained from the test plates through, and local to, the weld repairs using the deep hole drilling technique. Comparisons between the measurements and the finite element predictions generally showed good agreement, thus providing confidence in the method

  7. Effect of the weld groove shape and pass number on residual stresses in butt-welded pipes

    International Nuclear Information System (INIS)

    Sattari-Far, I.; Farahani, M.R.

    2009-01-01

    This study used finite element techniques to analyze the thermo-mechanical behaviour and residual stresses in butt-welded pipes. The residual stresses were also measured in some welds by using the Hole-Drilling method. The results of the finite element analysis were compared with experimentally measured data to evaluate the accuracy of the finite element modelling. Based on this study, a finite element modelling procedure with reasonable accuracy was developed. The developed FE modelling was used to study the effects of weld groove shape and weld pass number on welding residual stresses in butt-welded pipes. The hoop and axial residual stresses in pipe joints of 6 and 10 mm thickness of different groove shapes and pass number were studied. It is shown that these two parameters may have significant effects on magnitude and distribution of residual stresses in welded pipes.

  8. Mapping residual and internal stress in materials by neutron diffraction

    International Nuclear Information System (INIS)

    Withers, Ph.J.

    2007-01-01

    Neutron diffraction provides one of the few means of mapping residual stresses deep within the bulk of materials and components. This article reviews the basic scientific methodology by which internal strains and stresses are inferred from recorded diffraction peaks. Both conventional angular scans and time-of-flight measurements are reviewed and compared. Their complementarity with analogous synchrotron X-ray methods is also highlighted. For measurements to be exploited in structural integrity calculations underpinning the safe operation of engineering components, measurement standards have been defined and the major findings are summarised. Examples are used to highlight the unique capabilities of the method showing how it can provide insights ranging from the basic physics of slip mechanisms in hexagonal polycrystalline materials, through the materials optimisation of stress induced transformations in smart nano-materials, to the industrial introduction of novel friction welding processes exploiting stress residual measurements transferred from prototype sub-scale tests to the joining of full-scale aero-engine assemblies. (author)

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

    Science.gov (United States)

    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

  10. Improvement in accuracy of the measurements of residual stresses due to circumferential welds in thin-walled pipe using Rayleigh wave method

    International Nuclear Information System (INIS)

    Akhshik, Siamak; Moharrami, Rasool

    2009-01-01

    To achieve an acceptable safety in many industrial applications such as nuclear power plants and power generation, it is extremely important to gain an understanding of the magnitudes and distributions of the residual stresses in a pipe formed by joining two sections with a girth butt weld. Most of the methods for high-accuracy measurement of residual stress are destructive. These destructive measurement methods cannot be applied to engineering systems and structures during actual operation. In this paper, we present a method based on the measurement of ultrasonic Rayleigh wave velocity variations versus the stress state for nondestructive evaluation of residual stress in dissimilar pipe welded joint. We show some residual stress profile obtained by this method. These are then compared with other profiles determined using a semi-destructive technique (hole-drilling) that makes it possible to check our results. According to the results, we also present a new method for adjusting the ultrasonic measurements to improve the agreement with the results obtained from other techniques.

  11. Residual stresses measurement by using ring-core method and 3D digital image correlation technique

    International Nuclear Information System (INIS)

    Hu, Zhenxing; Xie, Huimin; Zhu, Jianguo; Wang, Huaixi; Lu, Jian

    2013-01-01

    Ring-core method/three-dimensional digital image correlation (3D DIC) residual stresses measurement is proposed. Ring-core cutting is a mechanical stress relief method, and combining with 3D DIC system the deformation of the specimen surface can be measured. An optimization iteration method is proposed to obtain the residual stress and rigid-body motion. The method has the ability to cut an annular trench at a different location out of the field of view. A compression test is carried out to demonstrate how residual stress is determined by using 3D DIC system and outfield measurement. The results determined by the approach are in good agreement with the theoretical value. Ring-core/3D DIC has shown its robustness to determine residual stress and can be extended to application in the engineering field. (paper)

  12. Effects of interface edge configuration on residual stress in the bonded structures for a divertor application

    International Nuclear Information System (INIS)

    Kitamura, K.; Nagata, K.; Shibui, M.; Tachikawa, N.; Araki, M.

    1998-01-01

    Residual stresses in the interface region, that developed at the cool down during the brazing, were evaluated for several bonded structures to assess the mechanical strength of the bonded interface, using thermoelasto-plastic stress analysis. Normal stress components of the residual stresses around the interface edge of graphite-copper (C-Cu) bonded structures were compared for three types of bonded features such as flat-type, monoblock-type and saddle-type. The saddle-type structure was found to be favorable for its relatively low residual stress, easy fabrication accuracy on bonded interface and armor replacement. Residual stresses around the interface edge in three armor materials/copper bonded structures for a divertor plate were also examined for the C-Cu, tungsten-copper (W-Cu) and molybdenum alloy-copper (TZM-Cu), varying the interface wedge angle from 45 to 135 . An optimal bonded configuration for the least value of residual stress was found to have a wedge angle of 45 for the C-Cu, and 135 for both the W-Cu and TZM-Cu bonded ones. (orig.)

  13. Feasibility of Residual Stress Nondestructive Estimation Using the Nonlinear Property of Critical Refraction Longitudinal Wave

    Directory of Open Access Journals (Sweden)

    Yu-Hua Zhang

    2017-01-01

    Full Text Available Residual stress has significant influence on the performance of mechanical components, and the nondestructive estimation of residual stress is always a difficult problem. This study applies the relative nonlinear coefficient of critical refraction longitudinal (LCR wave to nondestructively characterize the stress state of materials; the feasibility of residual stress estimation using the nonlinear property of LCR wave is verified. The nonlinear ultrasonic measurements based on LCR wave are conducted on components with known stress state to calculate the relative nonlinear coefficient. Experimental results indicate that the relative nonlinear coefficient monotonically increases with prestress and the increment of relative nonlinear coefficient is about 80%, while the wave velocity only decreases about 0.2%. The sensitivity of the relative nonlinear coefficient for stress is much higher than wave velocity. Furthermore, the dependence between the relative nonlinear coefficient and deformation state of components is found. The stress detection resolution based on the nonlinear property of LCR wave is 10 MPa, which has higher resolution than wave velocity. These results demonstrate that the nonlinear property of LCR wave is more suitable for stress characterization than wave velocity, and this quantitative information could be used for residual stress estimation.

  14. Standard test method for verifying the alignment of X-Ray diffraction instrumentation for residual stress measurement

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2010-01-01

    1.1 This test method covers the preparation and use of a flat stress-free test specimen for the purpose of checking the systematic error caused by instrument misalignment or sample positioning in X-ray diffraction residual stress measurement, or both. 1.2 This test method is applicable to apparatus intended for X-ray diffraction macroscopic residual stress measurement in polycrystalline samples employing measurement of a diffraction peak position in the high-back reflection region, and in which the θ, 2θ, and ψ rotation axes can be made to coincide (see Fig. 1). 1.3 This test method describes the use of iron powder which has been investigated in round-robin studies for the purpose of verifying the alignment of instrumentation intended for stress measurement in ferritic or martensitic steels. To verify instrument alignment prior to stress measurement in other metallic alloys and ceramics, powder having the same or lower diffraction angle as the material to be measured should be prepared in similar fashion...

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

    Energy Technology Data Exchange (ETDEWEB)

    Kato, T.; Momma, A.; Nagata, S.; Kasuga, Y. [Electrotechnical Lab., Ibaraki (Japan)

    1996-12-31

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

  16. Analysis of Residual Stress and Deformation of Rolling Strengthen Crankshaft Fillet

    Directory of Open Access Journals (Sweden)

    Han Shaojun

    2016-01-01

    Full Text Available Based on the analysis of crankshaft fillet rolling process, used ANSYS finite element analysis software to conduct the elastic-plastic mechanical simulation of crankshaft rolling process, and gained the variation law of the residual stress and plastic deformation in the radial path of the fillet under different rolling laps and rolling pressure. Established the relationship between the rolling pressure and the plastic deformation and residual stress of the fillet, and provided theoretical support for the evaluation and detection of the crankshaft rolling quality.

  17. Effect of constraint condition and internal medium on residual stress under overlay welding for dissimilar metal welding

    International Nuclear Information System (INIS)

    Song, Tae Kwang; Kim, Yun Jae; Lee, Kyoung Soo; Park, Chi Yong; Kim, Jong Sung; Kim, Jin Weon

    2007-01-01

    In nuclear power plants, residual stress of dissimilar metal weld propagates cracks in the weld metal which is susceptible to stress corrosion cracking. Overlay welding is a process widely used to mitigate residual stress replacing inside tensile stress by compression stress. However, according to the result of this study the effect of overlay welding on residual stress depends on both internal medium and constraint condition. The purpose of this study is to maximize the positive effect of overlay welding by finite element analyses

  18. Study on residual stress across the pipes' thickness using outer surface rapid heating. Development of pipe outer surface irradiated laser stress improvement process (L-SIP)

    International Nuclear Information System (INIS)

    Ohta, Takahiro; Terasaki, Toshio

    2009-01-01

    The new process called L-SIP (outer surface irradiated Laser Stress Improvement Process) is developed to improve the tensile residual stress of the inner surface near the butt welded joints of pipes in the compression stress. The temperature gradient occurs in the thickness of pipes in heating the outer surface rapidly by laser beam. By the thermal expansion difference between the inner surface and the outer surface, the compression plastic strain generates near the outer surface and the tensile plastic strain generates near the inner surface of pipes. The compression stress occurs near the inner surface of pipes by the plastic deformation. In this paper, the theoretical equation which calculates residual stress distribution from the inherent strain distribution in the thickness of pipes is derived. And, the relation between the distribution of temperature and the residual stress in the thickness is examined for various pipes size. (1) By rapidly heating from the outer surface, the residual stress near the inner surface of the pipe is improved to the compression stress. (2) Pipes size hardly affects the distribution of the residual stress in the stainless steel pipes for piping (JISG3459). (3) The temperature rising area from the outside is smaller, the area of the compression residual stress near the inner surface becomes wider. (author)

  19. Measurement of the residual stresses in a PWR Control Rod Drive Mechanism nozzle

    OpenAIRE

    Coules, Harry; Smith, David

    2018-01-01

    Residual stress in the welds that attach Control Rod Drive Mechanism nozzles into the upper head of a PWR reactor vessel can influence the vessel's structural integrity and initiate Primary Water Stress Corrosion Cracking. PWSCC at Alloy 600 CRDM nozzles has caused primary coolant leakage in operating PWRs. We have used Deep Hole Drilling to characterise residual stresses in a PWR vessel head. Measurements of the internal cladding and nozzle attachment weld showed that although modest tensile...

  20. Effect of texture and grain size on the residual stress of nanocrystalline thin films

    Science.gov (United States)

    Cao, Lei; Sengupta, Arkaprabha; Pantuso, Daniel; Koslowski, Marisol

    2017-10-01

    Residual stresses develop in thin film interconnects mainly as a result of deposition conditions and multiple thermal loading cycles during the manufacturing flow. Understanding the relation between the distribution of residual stress and the interconnect microstructure is of key importance to manage the nucleation and growth of defects that can lead to failure under reliability testing and use conditions. Dislocation dynamics simulations are performed in nanocrystalline copper subjected to cyclic loading to quantify the distribution of residual stresses as a function of grain misorientation and grain size distribution. The outcomes of this work help to evaluate the effect of microstructure in thin films failure by identifying potential voiding sites. Furthermore, the simulations show how dislocation structures are influenced by texture and grain size distribution that affect the residual stress. For example, when dislocation loops reach the opposite grain boundary during loading, these dislocations remain locked during unloading.

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

    Science.gov (United States)

    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.

  2. Effects of thermal residual stresses and fiber packing on deformation of metal-matrix composites

    International Nuclear Information System (INIS)

    Nakamura, T.; Suresh, S.

    1993-01-01

    The combined effects of thermal residual stresses and fiber spatial distribution on the deformation of a 6061 aluminum alloy containing a fixed concentration unidirectional boron fibers have been analyzed using detailed finite element models. The geometrical structure includes perfectly periodic, uniformly space fiber arrangements in square and hexagonal cells, as well as different cells in which either 30 or 60 fibers are randomly placed in the ductile matrix. The model involves an elastic-plastic matrix, elastic fibers, and mechanically bonded interfaces. The results indicate that both fiber packing and thermal residual stresses can have a significant effect on the stress-strain characteristics of the composite. The thermal residual stresses cause pronounced matrix yielding which also influences the apparent overall stiffness of the composite during the initial stages of subsequent far-field loading along the axial and transverse direction. Furthermore, the thermal residual stresses apparently elevate the flow stress of the composite during transverse tension. Such effects can be traced back to the level of constraint imposed on the matrix by local fiber spacing. The implications of the present results to the processing of the composites are also briefly addressed

  3. Relaxation of residual stress in MMC after combined plastic deformation and heat treatment

    International Nuclear Information System (INIS)

    Bruno, G.; Ceretti, M.; Girardin, E.; Giuliani, A.; Manescu, A.

    2004-01-01

    Neutron Diffraction shows that plastic pre-deformation and heat treatments have opposite effects on the residual stress in Al-SiC p composites. The thermal micro residual stress is relaxed or even reversed by pre-strains above 0.2%, but restored by heat treatments. The sense of relaxation changes above 400 deg. C (the mixing temperature)

  4. Reconstruction of the residual stresses in a hyperelastic body using ultrasound techniques

    KAUST Repository

    Joshi, Sunnie

    2013-09-01

    This paper focuses on a novel approach for characterizing the residual stress field in soft tissue using ultrasound interrogation. A nonlinear inverse spectral technique is developed that makes fundamental use of the finite strain nonlinear response of the material to a quasi-static loading. The soft tissue is modeled as a nonlinear, prestressed and residually stressed, isotropic, slightly compressible elastic body with a rectangular geometry. A boundary value problem is formulated for the residually stressed and prestressed soft tissue, the boundary of which is subjected to a quasi-static pressure, and then an idealized model for the ultrasound interrogation is constructed by superimposing small amplitude time harmonic infinitesimal vibrations on static finite deformation via an asymptotic construction. The model is studied, through a semi-inverse approach, for a specific class of deformations that leads to a system of second order differential equations with homogeneous boundary conditions of Sturm-Liouville type. By making use of the classical theory of inverse Sturm-Liouville problems, and root finding and optimization techniques, several inverse spectral algorithms are developed to approximate the residual stress distribution in the body, given the first few eigenfrequencies of several induced static pressures. © 2013 Elsevier Ltd. All rights reserved.

  5. Residual stress measurements in a ferritic steel/In625 superalloy dissimilar metal weldment using neutron diffraction and deep-hole drilling

    International Nuclear Information System (INIS)

    Skouras, A.; Paradowska, A.; Peel, M.J.; Flewitt, P.E.J.; Pavier, M.J.

    2013-01-01

    This paper reports the use of non-invasive and semi-invasive techniques to measure the residual stresses in a large dissimilar weldment. This took the form of a butt weld between two sections of a P92 steel pipe, joined using an In625 welding consumable. Residual stress measurements have been carried out on the 30 mm thick welded pipe using the deep-hole drilling technique to characterise the through wall section residual stress distribution for the weld metal, HAZ and parent material. In addition, neutron diffraction measurements have been carried out within the weld zone. Diffraction patterns presented a high intensity and sharp peaks for the base P92 steel material. However measurements in the weld superalloy material were proven problematic as very weak diffraction patterns were observed. A thorough examination of the weld material suggested that the likely cause of this phenomenon was texture in the weld material created during the solidification phase of the welding procedure. This paper discusses the challenges in the execution and interpretation of the neutron diffraction results and demonstrates that realistic measurements of residual stresses can be achieved, in complex dissimilar metal weldments. Highlights: ► One of the few papers to measure residual stresses on dissimilar metal welds. ► Paper managed to provide realistic measurements of residual stresses using the DHD and ND technique. ► Results of this study have demonstrated the effect of texture during the ND measurements.

  6. Numerical investigation on residual stress distribution and evolution during multipass narrow gap welding of thick-walled stainless steel pipes

    International Nuclear Information System (INIS)

    Liu, C.; Zhang, J.X.; Xue, C.B.

    2011-01-01

    Research highlights: → We performed pass-by-pass simulation of stresses for welding of thick-walled pipes. → The distributions and evolution of the residual stresses are demonstrated. → After the groove is filled to a height, the through-wall stress is almost unchanged. - Abstracts: The detailed pass-by-pass finite element (FE) simulation is presented to investigate the residual stresses in narrow gap multipass welding of pipes with a wall thickness of 70 mm and 73 weld passes. The simulated residual stress on the outer surface is validated with the experimental one. The distribution and evolution of the through-wall residual stresses are demonstrated. The investigated results show that the residual stresses on the outer and inner surfaces are tensile in the weld zone and its vicinity. The through-wall axial residual stresses at the weld center line and the HAZ line demonstrate a distribution of bending type. The through-wall hoop residual stress within the weld is mostly tensile. After the groove is filled to a certain height, the peak tensile stresses and the stress distribution patterns for both axial and hoop stresses remain almost unchanged.

  7. Optimal temperature profiles for minimum residual stress in the cure process of polymer composites

    CSIR Research Space (South Africa)

    Gopal, AK

    2000-01-01

    Full Text Available include the minimum residual stresses, minimum cure cycle lime and full degree of cure. The development of residual stresses during the cure cycle is one of the most important problems as they affect the strength and the mechanical properties of the final...

  8. Polycrystalline models for the calculation of residual stresses in zirconium alloys tubes

    International Nuclear Information System (INIS)

    Signorelli, J.W.; Turner, P.A.; Lebensohn, R.A.; Pochettino, A.A.

    1995-01-01

    Tubes made of different Zirconium alloys are used in various types of reactors. The final texture of tubes as well as the distribution of residual stresses depend on the mechanical treatments done during their manufacturing process. The knowledge and prediction of both the final texture and the distribution of residual stresses in a tube for nuclear applications are of outstanding importance in relation with in-reactor performance of the tube, especially in what concerns to its irradiation creep and growth behaviour. The viscoplastic and the elastoplastic self consistent polycrystal models are used to investigate the influence of different mechanical treatments, performed during rolling processes on the final distribution of intergranular residual stresses of zirconium alloys tubes. The residual strains predictions with both formulations show a non linear dependence with the orientation, but they are qualitatively different. This discrepancy could be explain in terms of the relative plastic activity between the -type and -type deformation modes predicted with the viscoplastic and elastoplastic models. (author). 10 refs., 4 figs., 1 tab

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

    Science.gov (United States)

    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.

  10. X-ray evaluation of residual stress distributions within surface machined layer generated by surface machining and sequential welding

    International Nuclear Information System (INIS)

    Taniguchi, Yuu; Okano, Shigetaka; Mochizuki, Masahito

    2017-01-01

    The excessive tensile residual stress generated by welding after surface machining may be an important factor to cause stress corrosion cracking (SCC) in nuclear power plants. Therefore we need to understand and control the residual stress distribution appropriately. In this study, residual stress distributions within surface machined layer generated by surface machining and sequential welding were evaluated by X-ray diffraction method. Depth directional distributions were also investigated by electrolytic polishing. In addition, to consider the effect of work hardened layer on the residual stress distributions, we also measured full width at half maximum (FWHM) obtained from X-ray diffraction. Testing material was a low-carbon austenitic stainless steel type SUS316L. Test specimens were prepared by surface machining with different cutting conditions. Then, bead-on-plate welding under the same welding condition was carried out on the test specimens with different surface machined layer. As a result, the tensile residual stress generated by surface machining increased with increasing cutting speed and showed nearly uniform distributions on the surface. Furthermore, the tensile residual stress drastically decreased with increasing measurement depth within surface machined layer. Then, the residual stress approached 0 MPa after the compressive value showed. FWHM also decreased drastically with increasing measurement depth and almost constant value from a certain depth, which was almost equal regardless of the machining condition, within surface machined layer in all specimens. After welding, the transverse distribution of the longitudinal residual stress varied in the area apart from the weld center according to machining conditions and had a maximum value in heat affected zone. The magnitude of the maximum residual stress was almost equal regardless of the machining condition and decreased with increasing measurement depth within surface machined layer. Finally, the

  11. Residual stress analysis on materials with steep stress gradient by using X-ray incidence at higher angles

    International Nuclear Information System (INIS)

    Ohya, Shin-ichi; Yoshioka, Yasuo; Maeno, Shigeki

    1996-01-01

    X-ray stress measurements for isotropic polycrystalline are materials are usually carried out by the sin 2 ψ method under the assumption of no stress gradient in X-ray penetration depth. When a steep stress gradient exists in the vicinity of surface layer, however, non-linear sin 2 ψ relation is observed and the sin 2 ψ method cannot be applied on such cases. Although several X-ray stress analyzers have been developed for materials with steep stress gradient in the surface layer, it is desirable to use diffraction data at higher incident angles of ψ 0 as possible as close on 90 degrees in order to determine the both values of surface stress and stress gradient with high accuracy. In the present study, an X-ray stress analyzer based on Ω geometry was fabricated to enable X-ray incidence at higher angle of ψ 0 . The X-ray detector was positioned on -η side against X-ray incident beam. Both of the residual surface stress and stress gradient were determined by use of the COSψ method on shot-peened steel and silicon nitride specimens. This prototype stress analyzer was found effective to perform a biaxial or triaxial stress analysis. (author)

  12. In-situ X-ray residual stress measurement on a peened alloy 600 weld metal at elevated temperature under tensile load

    International Nuclear Information System (INIS)

    Yunomura, Tomoaki; Maeguchi, Takaharu; Kurimura, Takayuki

    2014-01-01

    In order to verify stability of residual stress improvement effect of peeing for mitigation of stress corrosion cracking in components of PWR plant, relaxation behavior of residual stress induced by water jet peening (WJP) on surface of alloy 600 weld metal (alloy 132) was investigated by in-situ X-ray residual stress measurement under thermal aging and stress condition considered for actual plant operation. Surface residual stress change was observed at the early stage of thermal aging at 360°C, but no significant further stress relaxation was observed after that. Applied stress below yield stress does not significantly affect stress relaxation behavior of surface residual stress. For the X-ray residual stress measurement, X-ray stress constant at room temperature for alloy 600 was determined experimentally with several surface treatment and existence of applied strain. The X-ray stress constant at elevated temperatures were extrapolated theoretically based on the X-ray stress constant at room temperature for alloy 600. (author)

  13. Residual stresses in high temperature corrosion of pure zirconium using elasto-viscoplastic model: Application to the deflection test in monofacial oxidation

    Science.gov (United States)

    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.

  14. Estimation of residual stress in welding of dissimilar metals at nuclear power plants using cascaded support vetor regression

    Energy Technology Data Exchange (ETDEWEB)

    Koo, Young Do; Yoo, Kwae Hwan; Na, Man Gyun [Dept. of Nuclear Engineering, Chosun University, Gwangju (Korea, Republic of)

    2017-06-15

    Residual stress is a critical element in determining the integrity of parts and the lifetime of welded structures. It is necessary to estimate the residual stress of a welding zone because residual stress is a major reason for the generation of primary water stress corrosion cracking in nuclear power plants. That is, it is necessary to estimate the distribution of the residual stress in welding of dissimilar metals under manifold welding conditions. In this study, a cascaded support vector regression (CSVR) model was presented to estimate the residual stress of a welding zone. The CSVR model was serially and consecutively structured in terms of SVR modules. Using numerical data obtained from finite element analysis by a subtractive clustering method, learning data that explained the characteristic behavior of the residual stress of a welding zone were selected to optimize the proposed model. The results suggest that the CSVR model yielded a better estimation performance when compared with a classic SVR model.

  15. Process for measuring residual stresses

    International Nuclear Information System (INIS)

    Elfinger, F.X.; Peiter, A.; Theiner, W.A.; Stuecker, E.

    1982-01-01

    No single process can at present solve all problems. The complete destructive processes only have a limited field of application, as the component cannot be reused. However, they are essential for the basic determination of stress distributions in the field of research and development. Destructive and non-destructive processes are mainly used if investigations have to be carried out on original components. With increasing component size, the part of destructive tests becomes smaller. The main applications are: quality assurance, testing of manufactured parts and characteristics of components. Among the non-destructive test procedures, X-raying has been developed most. It gives residual stresses on the surface and on surface layers near the edges. Further development is desirable - in assessment - in measuring techniques. Ultrasonic and magnetic crack detection processes are at present mainly used in research and development, and also in quality assurance. Because of the variable depth of penetration and the possibility of automation they are gaining in importance. (orig./RW) [de

  16. Development of a micrometre-scale radiographic measuring method for residual stress analysis

    International Nuclear Information System (INIS)

    Moeller, D.

    1999-01-01

    The radiographic method described uses micrometre X-ray diffraction for high-resolution residual stress analysis in single crystals. The focus is on application of two x-ray optics (glass capillaries) for shaping a sufficiently fine and intensive primary beam. Due to application of a proper one-grain measuring and analysis method, the resolution results are applicable to the characteristic grain sizes of many materials. (orig.) [de

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

    Science.gov (United States)

    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.

  18. Residual Stress Analysis of Severe Plastic Deformed Materials using the Finite Element Method and the Neutron Diffraction Method

    International Nuclear Information System (INIS)

    Kang, Mi Hyun; Seong, Back Suck; Kim, Hyoung Seop

    2009-01-01

    Severe plastic deformation (SPD) is one of the most promising top-down techniques, moving towards industrialization to fabricate bulk ultrafine grain materials. The strain distribution and deformation behavior during the ECAP (equal channel angular pressing), influenced by tool angles, friction and material behavior, was studied through experimental and numerical analyses. The residual stress of work piece which was straight before ECAP produces many serious problems in the next processing e.g. input of the work piece for the next ECAP. The bent work piece needs additional straightening or surface polishing even if the amount of bending is small, and residual stress need to be released before service applications. Residual stress, particularly tensile residual stress can be a very important factor in affecting the reliability and integrity of working parts. The formation of tensile residual stress may result in initiation of fatigue cracks, stress corrosion cracking, or other types of fracture. Hence, residual stress and resulting bending need to be controlled during ECAP. Thus, in current study the bending behavior and the residual stress of the work piece in ECAP are analyzed through experimental and finite element analyses by considering the effects of material, geometric, and processing parameters individually. The stress states in the ECAP processed work piece were measured by the non-destructive way using neutron diffraction. Efforts were made to suggest the alternate routes to reduce the residual stress and bending of work piece in ECAP

  19. Effects of stop–start features on residual stresses in a multipass austenitic stainless steel weld

    International Nuclear Information System (INIS)

    Turski, M.; Francis, J.A.; Hurrell, P.R.; Bate, S.K.; Hiller, S.; Withers, P.J.

    2012-01-01

    In this article we describe experiments that characterise and quantify the localised perturbations in residual stress associated with both ramped and abrupt stop–start features in a multipass weld. Residual stress distributions in AISI Grade 304L/308L stainless steel groove-welded specimens, containing weld interruptions that were introduced in a controlled manner, have been characterised using both neutron diffraction and the incremental deep hole drilling method. The extent to which the localised stresses associated with the interruptions were annealed by overlayed passes was also assessed. The results suggest that, regardless of the type of interruption, there can be significant localised increases in residual stress if the stop–start feature is left exposed. If further weld passes are deposited, then the localised increases in stress are likely to persist if the interruption was abrupt, whereas for a ramped interruption they may be dissipated. - Highlights: ► In this study the residual stress-field surrounding weld interruptions was measured. ► Localised stresses were found to increase at weld interruptions. ► Both ramped and abrupt weld interruptions were investigated. ► After subsequent weld passes, localised stresses persisted for abrupt interruptions. ► After subsequent weld passes, localised stresses dissipated for ramped interruptions.

  20. Characterization of residual stresses generated during inhomogeneous plastic deformation

    DEFF Research Database (Denmark)

    Lorentzen, T.; Faurholdt, T.; Clausen, B.

    1998-01-01

    Residual stresses generated by macroscopic inhomogeneous plastic deformation are predicted by an explicit finite element (FE) technique. The numerical predictions are evaluated by characterizing the residual elastic strains by neutron diffraction using two different (hkl) reflections. Intergranular...... compare well and verify the capability of the numerical technique as well as the possibilities of experimental validation using neutron diffraction. The presented experimental and numerical approach will subsequently be utilized for the evaluation of more complicated plastic deformation processes...

  1. Parametric study for welding residual stresses in nozzle of nuclear power plants using finite element method

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Wan Jae; Lee, Kyoung Soo; Kim, Tae Ryong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Song, Tae Kwang [Korea Univ., Seoul (Korea, Republic of)

    2008-07-01

    Distribution of welding residual stresses are mainly characterized by degrees and frequencies of thermal loads applied to materials. However, other effects as component size and clamping condition can also affect stress distributions to a certain extent thus careful manipulation of these parameters based on clear understanding of how they affect residual stresses distributions and why can be additional measure to mitigate residual stresses. This paper discusses aforementioned issues for the case of safety and relief nozzle in nuclear power plant through finite element analysis.

  2. Residual stress effects on the impact resistance and strength of fiber composites

    Science.gov (United States)

    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.

  3. Residual stress evaluation and curvature behavior of aluminum 7050 peen forming processed

    International Nuclear Information System (INIS)

    Oliveira, Rene Ramos de

    2011-01-01

    Shot peening is a superficial cold work process used to increase the fatigue life evaluated by residual stress measurements. The peen forming process is a variant of the shot peening process, where a curvature in the plate is obtained by the compression of the grains near to the surface. In this paper, the influence of the parameters such as: pressure of shot, ball shot size and thickness of aluminum 7050 samples with respect to residual stress profile and resulting arc height was studied. The evaluation of the residual stress profile was obtained by sin 2 ψ method. The results show that the formation of the curvature arc height is proportional to the shot peening pressure, of spheres size and inversely proportional to the thickness of the sample, and that stress concentration factor is larger for samples shot peened with small balls. On final of this paper presents an additional study on micro strain and average crystallite size, which can evaluate the profile of the samples after blasting. (author)

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

    Science.gov (United States)

    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

  5. Effect of cryogenic treatment on distribution of residual stress in case carburized En 353 steel

    International Nuclear Information System (INIS)

    Bensely, A.; Venkatesh, S.; Mohan Lal, D.; Nagarajan, G.; Rajadurai, A.; Junik, Krzysztof

    2008-01-01

    The effect of cryogenic treatment on the distribution of residual stress in the case carburized steel (En 353) was studied using X-ray diffraction technique. Two types of cryogenic treatment: shallow cryogenic treatment (193 K) and deep cryogenic treatment (77 K) were adopted, as a supplement to conventional heat treatment. The amount of retained austenite in conventionally heat-treated, shallow cryogenically treated and deep cryogenically treated samples was found to be 28%, 22% and 14%, respectively. The conventionally heat-treated, shallow cryogenically treated and deep cryogenically treated samples in untempered condition had a surface residual stress of -125 MPa, -115 MPa and -235 MPa, respectively. After tempering the conventionally heat-treated, shallow cryogenically treated and deep cryogenically treated samples had a surface residual stress of -150 MPa, -80 MPa and -80 MPa, respectively. A comparative study of the three treatments revealed that there was an increase in the compressive residual stress in steel that was subjected to cryogenic treatment prior to tempering. The experimental investigation revealed that deep cryogenically treated steel when subjected to tempering has undergone a reduction in compressive residual stress. Such stress relieving behaviour was mainly due to the increased precipitation of fine carbides in specimens subjected to DCT with tempering

  6. Effect of prior machining deformation on the development of tensile residual stresses in weld-fabricated nuclear components

    International Nuclear Information System (INIS)

    Prevey, P.S.; Mason, P.W.; Hornbach, D.J.; Molkenthin, J.P.

    1996-01-01

    Austenitic alloy weldments in nuclear systems may be subject to stress-corrosion cracking (SCC) failure if the sum of residual and applied stresses exceeds a critical threshold. Residual stresses developed by prior machining and welding may either accelerate or retard SCC, depending on their magnitude and sign. A combined x-ray diffraction and mechanical procedure was used to determine the axial and hoop residual stress and yield strength distributions into the inside-diameter surface of a simulated Alloy 600 penetration J-welded into a reactor pressure vessel. The degree of cold working and the resulting yield strength increase caused by prior machining and weld shrinkage were calculated from the line-broadening distributions. Tensile residual stresses on the order of +700 MPa were observed in both the axial and the hoop directions at the inside-diameter surface in a narrow region adjacent to the weld heat-affected zone. Stresses exceeding the bulk yield strength were found to develop due to the combined effects of cold working of the surface layers during initial machining and subsequent weld shrinkage. The residual stress and cold work distributions produced by prior machining were found to influence strongly the final residual stress state developed after welding

  7. Bandgap tuning with thermal residual stresses induced in a quantum dot.

    Science.gov (United States)

    Kong, Eui-Hyun; Joo, Soo-Hyun; Park, Hyun-Jin; Song, Seungwoo; Chang, Yong-June; Kim, Hyoung Seop; Jang, Hyun Myung

    2014-09-24

    Lattice distortion induced by residual stresses can alter electronic and mechanical properties of materials significantly. Herein, a novel way of the bandgap tuning in a quantum dot (QD) by lattice distortion is presented using 4-nm-sized CdS QDs grown on a TiO2 particle as an application example. The bandgap tuning (from 2.74 eV to 2.49 eV) of a CdS QD is achieved by suitably adjusting the degree of lattice distortion in a QD via the tensile residual stresses which arise from the difference in thermal expansion coefficients between CdS and TiO2. The idea of bandgap tuning is then applied to QD-sensitized solar cells, achieving ≈60% increase in the power conversion efficiency by controlling the degree of thermal residual stress. Since the present methodology is not limited to a specific QD system, it will potentially pave a way to unexplored quantum effects in various QD-based applications. © 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  8. Dissimilar friction stir welds in AA5083-AA6082: The effect of process parameters on residual stress

    International Nuclear Information System (INIS)

    Steuwer, A.; Peel, M.J.; Withers, P.J.

    2006-01-01

    The effect of tool traverse and rotation speeds on the residual stresses are quantified for welds between non-age-hardening AA5083 and age-hardening AA6082 and compared to single alloy joints made from each of the two constituents. The residual stresses have been characterised non-destructively by neutron diffraction and synchrotron X-ray diffraction. The region around the weld line was characterised by significant tensile residual stress fields which are balanced by compressive stresses in the parent material. The rotation speed of the tool has been found to have a substantially greater influence than the transverse speed on the properties and residual stresses in the welds, particularly on the AA5083 side where the location of the peak stress moves from the stir zone to beyond the edge of the tool shoulder. The changes in residual stress are related to microstructural and hardness changes as determined in a previous study . In particular the larger stresses under the weld tool on the AA5083 side compared to the AA6082 side are related to a transient reduction in yield stress due to dissolution of the hardening precipitates during welding prior to natural aging after welding

  9. Effects of material non-linearity on the residual stresses in a dendritic silicon crystal ribbon

    Science.gov (United States)

    Ray, Sujit K.; Utku, Senol

    1990-01-01

    Thermal stresses developed in a dendritic silicon crystal ribbon have been shown to cause plastic deformation and residual stresses in the ribbon. This paper presents an implementation of a numerical model proposed for thermoelastoplastic behavior of a material. The model has been used to study the effects of plasticity of silicon on the residual stresses. The material properties required to implement this model are all assumed, and the response of the material to the variations in these assumed parameters of the constitutive law and in the finite element mesh is investigated. The steady state growth process is observed to be periodic with nonzero residual stresses. Numerical difficulties are also encountered in the computer solution process, resulting in sharp jumps and large oscillations in the stress responses.

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

    Science.gov (United States)

    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.

  11. Influence of the residual stresses on crack initiation in brittle materials and structures

    International Nuclear Information System (INIS)

    Henninger, C.

    2007-11-01

    Many material assemblies subjected to thermo-mechanical loadings develop thermal residual stresses which modify crack onset conditions. Besides if one of the components has a plastic behaviour, plastic residual deformations may also have a contribution. One of the issues in brittle fracture mechanics is to predict crack onset without any pre-existing defect. Leguillon proposed an onset criterion based on both a Griffth-like energetic condition and a maximum stress criterion. The analysis uses matched asymptotics and the theory of singularity. The good fit between the model and experimental measurements led on homogeneous isotropic materials under pure mechanical loading incited us to take into account residual stresses in the criterion. The comparison between the modified criterion and the experimental measurements carried out on an aluminum/epoxy assembly proves to be satisfying concerning the prediction of failure of the interface between the two components. Besides, it allows, through inversion, identifying the fracture properties of this interface. The modified criterion is also applied to the delamination of the tile/structure interface in the plasma facing components of the Tore Supra tokamak. Indeed thermal and plastic residual stresses appear in the metallic part of these coating tiles. (author)

  12. A novel cryogenic treatment for reduction of residual stresses in 2024 aluminum alloy

    Energy Technology Data Exchange (ETDEWEB)

    Araghchi, M., E-mail: M.Araghchi@ma.iut.ac.ir [Department of Materials Engineering, Malek Ashtar University of Technology, Isfahan (Iran, Islamic Republic of); Mansouri, H.; Vafaei, R. [Department of Materials Engineering, Malek Ashtar University of Technology, Isfahan (Iran, Islamic Republic of); Guo, Yina [Bernal Institute, University of Limerick, Limerick (Ireland)

    2017-03-24

    Residual stresses induced during quenching of aluminum alloys cause distortion and have a negative effect on their properties. The purpose of this study is to reduce the residual stresses and improve mechanical properties by using a novel cryogenic treatment. Water quenched samples were cooled down by immersion in liquid nitrogen at −196 °C, following by rapid heating in hot oil at 180 °C and finally they were artificially aged. Residual stresses was measured by the hole drilling strain gauge method. The mechanical properties and microstructure of a heat treated samples were investigated by means of hardness measurements, tensile tests and transmission electron microscopy. The results showed that this treatment can relieve up to 71% of the residual stresses compared to 29% related to the traditional cryogenic treatment that used boiling water as the reheating medium. In addition, there is a considerable increase of about 75 MPa in the ultimate tensile strength in comparison to the T6 heat-treated alloy. TEM observations revealed that the S′ precipitates were fine and uniformly distributed in the microstructure due to deformation during reheating in hot oil.

  13. Principles of the measurement of residual stress by neutron diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Webster, G A; Ezeilo, A N [Imperial Coll. of Science and Technology, London (United Kingdom). Dept. of Mechanical Engineering

    1996-11-01

    The presence of residual stresses in engineering components can significantly affect their load carrying capacity and resistance to fracture. In order to quantify their effect it is necessary to know their magnitude and distribution. Neutron diffraction is the most suitable method of obtaining these stresses non-destructively in the interior of components. In this paper the principles of the technique are described. A monochromatic beam of neutrons, or time of flight measurements, can be employed. In each case, components of strain are determined directly from changes in the lattice spacings between crystals. Residual stresses can then be calculated from these strains. The experimental procedures for making the measurements are described and precautions for achieving reliable results discussed. These include choice of crystal planes on which to make measurements, extent of masking needed to identify a suitable sampling volume, type of detector and alignment procedure. Methods of achieving a stress free reference are also considered. A selection of practical examples is included to demonstrate the success of the technique. (author) 14 figs., 1 tab., 18 refs.

  14. Principles of the measurement of residual stress by neutron diffraction

    International Nuclear Information System (INIS)

    Webster, G.A.; Ezeilo, A.N.

    1996-01-01

    The presence of residual stresses in engineering components can significantly affect their load carrying capacity and resistance to fracture. In order to quantify their effect it is necessary to know their magnitude and distribution. Neutron diffraction is the most suitable method of obtaining these stresses non-destructively in the interior of components. In this paper the principles of the technique are described. A monochromatic beam of neutrons, or time of flight measurements, can be employed. In each case, components of strain are determined directly from changes in the lattice spacings between crystals. Residual stresses can then be calculated from these strains. The experimental procedures for making the measurements are described and precautions for achieving reliable results discussed. These include choice of crystal planes on which to make measurements, extent of masking needed to identify a suitable sampling volume, type of detector and alignment procedure. Methods of achieving a stress free reference are also considered. A selection of practical examples is included to demonstrate the success of the technique. (author) 14 figs., 1 tab., 18 refs

  15. Residual stress measurements by X-ray and neutron diffractions in heat-treated SiCw/A2014 composites

    International Nuclear Information System (INIS)

    Ohnuki, Takahisa; Fujita, Motoo; Tomota, Yo; Ono, Masayoshi

    1998-01-01

    Residual stresses due to various heat treatments in a 22 volume percent SiC whisker/A2014 metal matrix composite (MMC) were measured by using X-ray and neutron diffractions. Micro residual stresses generated from the differences in thermal expansion coefficients of the constituents and macro residual stresses associated with different cooling rates in the outer and inner regions of an MMC specimen must be distinguished in X-ray stress measurements. The conventional sin 2 ψ method under an assumption of plane stress condition has been found not to be applicable to the present MMC, because interactions among whiskers in the X-ray penetrating area yields σ 33 where the x 3 -axis is normal with respect to specimen's surface. An average value of σ 33 can be measured by X-ray diffraction technique, but does not seem enough to evaluate micro residual stresses. It is found that neutron diffraction is the most powerful method to measure micro residual stresses in the constituents. Elastic residual strains obtained by neutron diffraction in solution treated or T6 heat treated samples show good agreements with predictions calculated by using Eshelby inclusion theory coupled with the Mori-Tanaka mean field concept, indicating that the influence of stress relaxation is negligible. In addition, internal stresses relaxations during holding at room temperature, slow cooling from solution treatment temperature, or subzero cooling are discussed. (author)

  16. Investigation of the influence on residual stresses of porosity in high temperature ZrO2 coatings on Ag tape for magnet technologies

    International Nuclear Information System (INIS)

    Arman, Yusuf; Aktas, Mehmet; Celik, Erdal; Mutlu, Ibrahim H.; Sayman, Onur

    2007-01-01

    The present paper reports on the effect on residual stresses of porosity in high temperature ZrO 2 coatings on Ag tape for magnet technologies. ZrO 2 coatings were fabricated on Ag tape substrate using a reel-to-reel sol-gel system. The microstructural evolution of high temperature ZrO 2 coatings was investigated by a scanning electron microscope (SEM). SEM observations revealed that ZrO 2 coatings with crack had some porosity and mosaic structure. Stress analysis was carried out on ZrO 2 coatings with porosity on Ag tape substrates under cryogenic conditions by using classical lamination theory (CLT) for elastic solution and finite element method (FEM) for elasto-plastic solution in the temperature range of 0 o C to -223 o C in liquid helium media. Because of the static equilibrium, tensile force is applied to the Ag substrate, by ZrO 2 coating. The stress component (σ x ) values change rapidly at coating-substrate interface owing to the different moduli of elasticity and thermal expansion coefficient. In spite of the thickness of Ag substrate, the stress components vary from tensile to compressive. In addition, along the thickness of ZrO 2 coating and Ag substrate system, the stress distribution changes linearly. FEM results demonstrate that the failure does not occur in ZrO 2 coating for all porosities due to its high yield strength

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

    Science.gov (United States)

    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.

  18. The treatment of residual stress in fracture assessment of pressure vessels

    International Nuclear Information System (INIS)

    Green, D.; Knowles, J.

    1992-01-01

    The treatment of weld residual stress in the fracture assessment of cylindrical pressure vessels is considered through partitioning the stress into membrane, bending and self-balancing through wall components. The influence of each on fracture behavior is discussed. Stress intensity factor solutions appropriate to each type of stress are presented. Short range, medium range and long range stress categories are identified according to simple rules relating the effect of increasing crack length to stress intensity factor and ligament net stress. Proposals are made on how the stress intensity factor from these stress types may be incorporated into a Kr, Lr based fracture assessment

  19. Mitigation of inside surface residual stress of type 304 stainless steel pipe welds by inside water cooling method

    International Nuclear Information System (INIS)

    Sasaki, R.

    1980-01-01

    The weld residual stress distributions, macro- and microstructures of heat affected zone and IGSCC susceptibility of Type 304 stainless steel pipe welds by natural and inside water cooling methods have been investigated. The residual stresses of pipe welds by the natural cooling method are high tensile on both the inside and the outside surface. While the residual stresses on the inside surface of pipe welds by the inside water cooling method are compressive in both axial and circumferential directions for each pipe size from 2 to 24 inch diameter. The sensitized zones of welds by the inside water cooling method are closer to the fusion line, much narrower and milder than those by the natural cooling method. According to the constant extension rate test results for specimens taken from the inside surface of pipe welds, the inside water cooled welds are more resistant to IGSCC than naturally cooled ones

  20. Analysis and modeling of simulated residual stress of mold injected plastic parts by using robust correlations

    OpenAIRE

    Vargas, Carlos; Sierra, Juan; Posada, Juan; Botero-Cadavid, Juan F.

    2017-01-01

    ABSTRACT The injection molding process is the most widely used processing technique for polymers. The analysis of residual stresses generated during this process is crucial for the part quality assessment. The present study evaluates the residual stresses in a tensile strength specimen using the simulation software Moldex3D for two polymers, polypropylene and polycarbonate. The residual stresses obtained under a simulated design of experiment were modeled using a robust multivariable regressi...