Finite element simulation of the residual stresses in high strength carbon steel butt weld incorporating solid-state phase transformation

This paper presents a sequentially coupled three-dimensional (3-D) thermal, metallurgical and mechanical finite element (FE) model to simulate welding residual stresses in high strength carbon steel butt weld considering solid-state phase transformation effects. The effects of phase transformation during welding on residual stress evolution are modeled by allowing for volumetric changes and the associated changes in yield stress due to austenitic and martensitic transformations. In the FE model, phase transformation plasticity is also taken into account. Moreover, preheat and inter-pass temperature are included in the modeling process. Based on the FE model, the effects of solid-state phase transformation on welding residual stresses are investigated. The results indicate the importance of incorporating solid-state phase transformation in the simulation of welding residual stresses in high strength carbon steel butt weld.     

Cruciform fillet welded joint fatigue strength improvements by weld metal phase transformations

Arc welding typically generates residual tensile stresses in welded joints, leading to deteriorated fatigue performance of these joints. Volume expansion of the weld metal at high temperatures followed by contraction during cooling induces a local tensile residual stress state. A new type of welding wire capable of inducing a local compressive residual stress state by means of controlled martensitic transformation at relatively low temperatures has been studied, and the effects of the transformation temperature and residual stresses on fatigue strength are discussed. In this study, several LTTW (Low Transformation‐Temperature Welding) wires have been developed and investigated to better characterize the effect of phase transformation on residual stress management in welded joints. Non‐load‐carrying cruciform fillet welded joints were prepared for measurement of residual stresses and fatigue testing. The measurement of the residual stresses of the three designed wires reveals a compressive residual stress near the weld toe. The fatigue properties of the new wires are enhanced compared to a commercially available wire.     

Simulation of mechanical behavior of multiphase TRIP steel taking account of transformation-induced plasticity

Due to the effect of transformation-induced plasticity, multiphase low alloy TRIP steel exhibits an enhanced combination of strength and ductility. Moreover, volume fractions of the constituents in TRIP steel vary during its plastic deformation. In this paper, a constitutive model for mechanical behavior of multiphase TRIP steel is presented. In the model, TRIP steel microstructure is decomposed into four individual constituents: austenite, martensite, bainitic ferrite and ferrite. Mechanical behavior of each individual phase is described by using physically-based model. On the basis of introducing transformation-induced plasticity (TRIP) strain into decomposition of total strain, stress–strain relation of multiphase composite is obtained by using mixture rule and Iso-W hypothesis. Kinetics of strain-induced martensitic transformation is described by a generalized form of Olson–Cohen model, which takes into account temperature and stress state. Moreover, a new method to describe evolving grain size of retained austenite due to martensitic transformation is developed. On the basis of presented model, mechanical behavior of multiphase steel is simulated by using finite element method. Parameters of the model are calibrated for different mixture laws used in calculation. The simulated results have a good agreement with those observed in experiments.     

Minimizing Stress and Distortion for Shafts and Discs by Controlled Quenching in a Field of Nozzles

A coupled gas‐dynamical and thermo‐mechanical model for simulation of the gas flow, gas and specimen temperature, phase, stress, strain, and displacement transient‐fields during quenching of cutting discs and shafts of steel is introduced. The material properties (e. g. density, conductivity, heat capacity, hardness) are obtained by homogenization procedures. The material behaviour is described as an extension of the classical J₂‐plasticity theory with the extension of temperature and phase fraction dependent yield criteria. The coupling effects such as dissipation, phase transformation enthalpy, and transformation induced plasticity (TRIP) are considered. Simulations were carried out for cutting discs of knives, and for shafts made of steel SAE 52100 with varying diameter. For the validation of the simulations, these work pieces were heated in a roller hearth kiln up to 850 °C, and than quenched in a field of nozzles in which the heat transfer coefficient was known and could be locally adjusted by the volume flow of each nozzle. The phase fractions, surface hardness, distortion, and residual stresses were measured. The simulated and measured results fit quite well. According to optimization‐simulations the shafts were quenched with a certain heat transfer coefficient distribution. The bigger diameter parts of the shaft were more intensively quenched by an increased gas flow so that the hardness profiles were equalized and the residual stresses at the edges were significantly reduced.     

Residual stresses in two laser surface melted stainless steels

Abstract

Residual stresses were studied in two laser surface melted stainless steels: one martensitic, Fe–12Cr–0·2C, and the other austenitic, Fe–17Cr–11Ni–2·5Mo (compositions in wt-%). Stresses were measured by X-ray diffractometry over a range of depths, processing conditions, and stress relieving heat treatments. The volume increase associated with the martensitic transformation develops compressive stresses in single tracks of the martensitic steel and modifies the subsurface stresses of the laser surface melted steel. However, interactions between tracks offset the compressive surface stresses at all but the slightest overlaps. Residual stresses in the martensitic steel are minimized by increasing the advance between tracks and are reduced to a lesser extent by increasing the beam diameter and decreasing the traverse velocity. The austenitic steel, undergoing no solid state phase transformation on cooling, develops tensile residual stresses of the order of the yield stress for all the processing conditions evaluated. Suitable stress relieving heat treatments were identified for each steel.

MST/422     

Microstructural and thermo-mechanical analysis of quench cracking during the production of bainitic–martensitic railway wheels

Quench cracking during the production of newly developed low carbon bainitic–martensitic (LCBM) rail wheels was investigated using a microstructural and thermo-mechanical Finite Element (FE) model. The stresses associated with quench cracking during martensite phase transformation were predicted under various quenching conditions for two different grades of LCBM steels with different kinetics of martensite phase transformation. The FE analyses showed that the likelihood of quench cracking can be reduced by using a low coolant spray intensity since the internal stresses generated during the martensitic phase transformation were found to be below the steel’s flow stress. The internal stresses were predicted to be even lower with a low carbon grade LCBM steel. The microstructural and thermo-mechanical model has been used to determine favourable quenching conditions that have the potential to reduce the propensity of quench cracking during the production of LCBM railway wheels.     

Nutzung von Low‐Transformation‐Temperature‐Werkstoffen (LTT) zur Eigenspannungsreduzierung im Elektronenstrahlschweißprozess

Low‐Transformation‐Temperature materials (LTT) were designed to reduce delay as well as residual tensile stress in welds on carbon‐manganese steels. Using the volume expansion effect during a martensitic transformation these materials counteract the volume shrinkage during cooling. While this positive effects on residual stress relief by Low‐Transformation‐Temperature‐alloys has been proven in various studies, these alloys have always been used in large volumes as additional filler material in electric arc welding processes. Modular heat fields initiated by an electron‐beam‐welding‐process offers the potential of a time‐activated initiation of compressive stresses triggered by phase transformation of Low‐Transformation‐Temperature‐alloys. Developing a technology able to reduce residual stress and thus the deformation of complex welded components is the aim. The first approach of Low‐Transformation‐Temperature‐material used in the electron beam process and its behaviour is presented here.     

On the interaction between transformation induced plasticity and the austenitic stainless steel anisotropy (AISI 304) under shear loading path

It is well known that for the AISI 304 austenitic stainless steel some parameters such as temperature, strain rate, material anisotropy and loading path are the main factors which strongly affect the kinetic of transformation induced plasticity (TRIP) in this material. In literature, tensile and compression tests represent the commonly experimental tools studied on this material. Under such type of loading, dissymmetry plastic behavior was obtained due to the martensitic kinetic evolution.The aim of the present work is to highlight the role of the TRIP phenomenon on the initial material anisotropy of the AISI 304 material using appropriate experimental framework. The cross-coupled effect of the phase transformation on initial anisotropy is studied through special loading test (simple shear test (SST)) conducted at various temperatures.     

Review: Low transformation temperature weld filler for tensile residual stress reduction

An attractive, alternative approach for the reduction of harmful residual stresses in weld zones is reviewed, which utilises low temperature, solid-state, displacive phase transformations in steel. The theory, latest concepts and practice for the design of such low transformation temperature (LTT) filler alloys are considered. By engineering the phase transformation temperature of the weld metal so as to take advantage of transformation expansion, the residual stress state within the weld zone can be significantly altered, most particularly where the weld thermally contracts with any movement of base parts constrained. To date, the technique has been shown to increase fatigue strength for some common weld geometries, which may enable engineering design codes to be favourably re-drafted where such LTT filler alloys are used.     

Temperature, stress and microstructure in 10Ni5CrMoV steel plate during air–arc cutting process

Although the air–arc cutting process has been widely used in the material processing engineering, little information about temperature, stress and microstructure in the plate air–arc cut is known. A three-dimensional finite element model including the material removal and the thermal effect of the arc is developed to study the temperature and stress fields of 10Ni5CrMoV steel plate during air–arc cutting process in this paper. The microstructures and micro-mechanical properties of the parts near the groove especially in heat affected zone (HAZ) are studied by experimental methods, and they also can be used as a method to verify the numerical results. Effects of stresses induced by air–arc cutting process on the initial residual stress fields of base materials are also researched. The results show that the cooling velocity in HAZ is higher than the one of the welding process for the same base material, and the zone with high temperature is very narrow, which means that the temperature gradients near the groove are very steep during the air–arc cutting process; this special temperature field depresses multiphase transformations and coarse microstructures. The evolution of the stress during the air–arc cutting is described, and the numerical results indicate that the characteristics of the evolution of stresses and the residual stresses distribution in the plate in air–arc cutting process seem to be similar to the ones of the butt welding for flat plates. The influences of air–arc cutting process on initial stress fields present two aspects: thermal effect and material removal effect, and the former plays a primary role. Both numerical temperature and stress fields are compared with the experimental ones. It is very important for researchers to clarify the temperatures, stresses and microstructures in the plate during air–arc cutting process, and understand fully the mechanism of influences of air–arc cutting on the plate; it is also very valuable for engineering application of the air–arc cutting process.     

Effect of Spraying Condition and Material Properties on the Residual Stress in Plasma Spraying

The thermomechanical behavior and the distribution of residual stresses due to thermal spraying of NiCoCrAlY coating were studied by thermomechanical finite element analysis. The effects of phase transformation due to solidifying process of coating particles, thickness and material properties of coating on the residual stresses were discussed. Results showed that residual stress decreases little with the stress relaxation due to the phase transformation. For the substrates with the same thickness, the residual stress increases with the increase in coating thickness. The state of residual stresses relates to the material properties of coating and substrate closely. The stress-induced failure model of coating is also discussed.     

Quantifying the metallurgical response of a nuclear steel to welding thermal cycles

Solid-state phase transformations can drastically influence the evolution of stress in welds due to the strains associated with the transformations and related changes in mechanical properties. As such, finite-element predictions of welding residual stresses need reliable materials data including, where applicable, information on phase transformation kinetics and phase- and temperature-dependent material properties. Owing to a scarcity of such data, many authors have used uncalibrated empirical modelling approaches for the prediction of welding residual stresses. This paper addresses this critical shortage for an important nuclear pressure vessel (SA508) steel. Austenite formation, grain growth and decomposition data are presented and subsequently used to calibrate transformation models. These models are shown to accurately predict microstructure and residual stresses for experimental test cases.

This paper is part of a Themed Issue on Measurement, modelling and mitigation of residual stress.     

Stress–phase-transformation interactions – basic principles,modelling, and calculation of internal stresses

Abstract

The two main effects of stress on phase transformation, kinetics modification and transformation plasticity, are reviewed for both diffusional and non-diffusional transformations. Results for these interactions during the pearlitic and martensitic transformation of steels under uniaxial tensile stress are analysed from a metallurgical point of view. These results are used to produce a model for a triaxial stress state, and in a finite element program for calculating internal stresses during quenching. Transformation plasticity is introduced in the calculation of internal stresses as an additional strain related to the stress state and to the progress of transformation, and the kinetics of martensitic transformation are also related to the stress state. The calculated results show that these phenomena have important consequences on the stress and plastic strain histories during quenching.

MST/9     

Influence of applying external stress during aging on martensitic transformation and the superelastic behavior of a Ni-rich NiTi alloy

Superelastic properties and martensitic transition temperatures of Ni_50.9Ti shape memory wires were studied after aging under different applied stresses at 450 °C for 45 min. The results indicate that applying external stresses during aging of Ni_50.9Ti shape memory wires changes the strain value and stress level of plateaus related to stress induced martensitic transformation. Furthermore, martensitic transformation sequences change after applying external stresses but transformation temperatures measured with DSC remain constant in samples aged under stresses up to 120 MPa. Applying stress of 60 MPa during aging enhances the superelastic properties by increasing the strain of plateaus during loading and unloading cycles. Applying stresses more than 60 MPa, decreases the strain of the plateau during unloading.     

Thermomechanical Analysis of Preheat Effect on Grade P91 Steel During GTA Welding

Effect of preheat on the thermal cycles, residual stress, and distortion during autogenous GTA welding of Grade P91 steel has been analyzed using FEM. Phase transformation effect on the residual stresses is also analyzed. Thermomechanical analysis has shown that preheat reduced the peak temperatures, cooling rate, and the distortion values. The phase transformation involving martensite during cooling resulted in typical “M” shaped residual stress profile with a reduction in peak tensile residual stress value and a wider distribution of residual stress. There is good agreement between the predicted and measured thermal cycles, residual stresses, and distortion of the P91 steel weld joint.     

约束态相变中TiNi形状记忆合金的马氏体自拉伸过程

研究了约束态加热过程中产生的回复力对TiNi形状记忆合金剩余马氏体的影响．结果表明，产生的回复力使剩余马氏体发生了塑性变形，使逆相变温度升高，剩余马氏体分数和其逆相变温度之间存在特定的函数关系．但是，外部约束条件的变化对马氏体的自拉伸过程所造成的剩余马氏体分数与其逆相变温度之间的关系影响很小．     

Analysis of the Transformation-induced Plasticity Effect during the Dynamic Deformation of High-manganese Steel

The transformation-induced plasticity(TRIP) effect and resistance characteristics to adiabatic shear failure at high strain rates of high-manganese steel were investigated by using scanning electron microscopy and electron backscattering diffraction. Results showed that the high-manganese steel exhibited excellent strain hardening effect and resistance to adiabatic shear failure because of the TRIP effect. The TRIP effect occurred during dynamic deformation and showed two distinct stages,namely,the smooth TRIP process before the formation of adiabatic shear band(ASB) and the inhibited TRIP process during further deformation. In the first stage,the martensitic transformation showed slight orientation dependence and weak variant selection,which promoted the TRIP effect. In the second stage,reverse martensitic transformation occurred. Adiabatic shear bands(ASBs) developed typical shear microtextures {111}<110>. In microtextures,two groups of fine grains are in a twin relationship and uniform distribution,which restrained the formation of holes and cracks within the ASBs and enhanced damage resistance after ASB formation.     

A multi-scale model of martensitic transformation plasticity

The remarkable mechanical engineering properties of many advanced steels, e.g. TRIP steels and metastable austenitic stainless steels, are related to their complex microstructural behaviour, resulting from the interaction between plastic deformation of the phases and the austenite to martensite phase transformation during thermomechanical loading. In this paper, a multi-scale physically-based model is presented for the prediction of such structure–property relations for materials exhibiting the martensite phase transformation during mechanical loading. The model incorporates several spatial levels: a macroscopic or engineering level, a mesoscale level of a single austenite grain and a microscale level of smaller domains within the austenite grain where the martensitic transformation takes place on particular crystallographic transformation systems. The model directly incorporates the coupling between elastic and plastic deformation of the phases and the transformation, as well as the dependence of the transformation on the (hydrostatic) stress state, grain orientation with respect to the loading and the history of deformation and transformation. The performance of the model is evaluated on several examples, illustrating the ability of the model to predict the orientation and stress-state dependence of the transformation. The developed model can be used for the systematic study of structure–property relations of these inherently multi-scale materials.