Finite Element Analysis of Modeling Residual Stress Distribution in All-position Duplex Stainless Steel Welded Pipe

On the basis of the thermal-elastic-plastic theory, a three-dimensional finite element numerical simulation is performed on the girth welded residual stresses of the duplex stainless steel pipe with ANSYS nonlinear finite element program for the first time. Three-dimensional FEM using mobile heat source for analysis transient temperature field and welding stress field in circumferential joint of pipes is founded. Distributions of axial and hoop residual stresses of the joint are investigated. The axial and the hoop residual stresses at the weld and weld vicinity on inner surface of pipes are tensile, and they are gradually transferred into compressive with the increase of the departure from the weld. The axial residual stresses at the weld and weld vicinity on outer surface of pipes is compressive while the hoop one is tensile. The distributions of residual stresses compared positive-circle with negative-circle show distinct symmetry. These results provide theoretical knowledge for the optimization of p     

Determination of residual stresses in three-layer alumina composites using an indentation technique

The distribution of residual stresses in three-layer reaction bonded alumina (RBAO) composites with 17.5 vol % zirconia in the inner layer and 40 vol % mullite in the outer layers was determined by an indentation technique. It could be shown that the outer layers are subject to a residual compressive stress while the inner layer is under a tensile stress. With increasing outer layer thickness, the residual compressive stress decreases, and the residual tensile stress increases. Compressive stresses up to 550 MPa were measured in this study. It was found that the residual stresses are not uniform throughout the layers. The magnitude of the stresses decreases with increasing distance from the interfaces. This is attributed to creep during cooling from the sintering temperature. This revised version was published online in September 2006 with corrections to the Cover Date.     

Eigenspannungsmessungen an unterschiedlich abgekohlten,kugelgestrahlten und torsionsschwellbeanspruchten Proben aus Federstahl

Residual Stress Measurements on Differently Decarburized, Shot Peened and Cyclic Torsional Loaded Specimens of a Spring Steel In addition to previous fatigue tests with the spring material 55 Cr 3, X-ray residual stress measurements were carried out on differently decarburized, shot peened and cyclic torsional loaded specimens. It was shown that longer duration of decarburization leads to higher residual tensile stress in the surface zone for not peened specimens. Shot peening, however, effects almost equal residual compressive stresses in the surface zone in spite of different starting conditions, with a slight decrease for specimens with a long duration of decarburization, which corresponds to the results of the fatigue tests. By cyclic torsional loading with mean stress the residual compressive stresses due to shot peening are diminished in the axial and circumferential directions. A main stress system is now to be found with an angle of 45° to axis, whereas the residual stresses in the s?₁-(tensile direction) retain their values, those in the s?₂-(compressive) direction are decreased distinctly.     

Influence of process parameters for induction hardening on residual stresses

Fatigue behaviour of induction hardened parts is largely dependent on the correct combination of hardening depth and the magnitude and distribution of residual compressive stresses in the surface layer. The objective of this work was to study experimentally the residual stresses at the surface layer of induction hardened cylindrical specimens. Two microstructures, quenched-tempered and normalised were investigated. The process parameters of induction hardening were varied to give a constant hardness penetration depth. The residual stresses were measured using the X-ray diffraction method. The investigated induction hardened samples showed a constant biaxial residual stress-state at the surface. The directions of the principal stresses deviated slightly from the defined circumferential and longitudinal directions. However, the shear stresses at the surface were of a small magnitude. This experimental investigation showed that the process parameters of induction hardening influence the residual stress-state of hardened parts to a great extent.     

Effect of residual stresses on the linear-elastic KI-T field for circumferential surface flaws in pipes

This paper describes the effect of four realistic residual stress patterns on the crack-front constraints for circumferential surface flaws in the wall of a pipe, characterized by the linear-elastic K_I-T stresses. The numerical representation of the residual stresses combines a thermal-induced eigenstrain field with a local mechanical traction applied over the interface between the heat affected zone and the remaining pipe. The verification study confirms the accuracy of this approach based on the analytical K_I solution for a 2-D crack under prescribed residual stresses. This study demonstrates low crack-front constraints near the deepest crack front for three typical residual stresses.     

Behaviour of stresses in circumferential butt welds of steel pipe under superimposed axial tension loading

A computational procedure is presented for analyzing behaviour of stresses in circumferential butt welds of carbon steel pipe subject to superimposed mechanical loading. Three-dimensional uncoupled thermo-mechanical finite element (FE) analysis method is developed in order to predict the weld residual stress states in circumferentially butt-welded steel pipe. The FE method is verified through the experimental work. Then, three-dimensional elastic–plastic FE analysis is carried out to investigate the behaviour of stresses in steel pipe circumferential welds undergoing superimposed axial tension loading using the weld residual stresses and plastic strains obtained from the thermo-mechanical FE method. The simulated results show that spatial variations of the weld residual stresses are present along the circumference and a rapid change of the residual stresses exists at the weld start/stop position, therefore three-dimensional FE analysis is essential to accurately simulate the circumferential welding of steel pipe. Moreover, when axial tension loading is applied to the circumferentially welded steel pipe, bending moment is generated at the weld area caused by the circumferential shrinkage of the weld during welding, thus affecting the axial and hoop stress evolutions in the course of mechanical loading.     

An improved back computation procedure for the parting-out step of a destructive method for measuring residual stresses in pipes

One method for measuring through the thickness residual stress distributions in welded pipes involves a destructive, three step laboratory procedure consisting of parting out, splitting, and layer removal operations. In the parting out step, a coupon of material is removed from the wall of the pipe while strain gauges on the inner and outer surfaces are monitored. In back computing the through the thickness residual stresses from the parting-out strain gauge data, it is generally assumed that stress changes through the thickness of the coupon vary as a straight line. If the circumferential dimension of the coupon is large compared to the thickness, this assumption is valid. However, in the case of a pipe, the circumferential dimension is usually limited to reduce curvature effects during the subsequent splitting and layer removal steps. If this dimension is too small, the assumption of straight line stress changes through the thickness can lead to serious inaccuracies. In this paper, the validity of the straight line assumption is examined over a range of conditions. To handle cases where the straight line assumption is not valid, a modified back computation procedure for the analysis of parting-out strain gauge data is developed and presented with numerical results.     

Surface strengthening and toughening of Si3N4/TiC layered composite by slip casting

Layered composite using monolithic Si₃N₄ as outer layers and Si₃N₄-15v/o TiC as inner core was fabricated by slip casting and pressureless sintering. As the composite is cooled from high sintering temperature, the difference in coefficients of thermal expansion between the constrained inner core and outer layer is expected to establish a compressive surface stress. The existence of this residual stress was verified by theoretical analysis and Vicker's indentation for the samples with various outer layer thickness. The layered composites exhibited greater strength, apparent fracture toughness and damage resistance due to the presence of compressive surface stresses in the layer.     

Optimization of a cold-working process for increasing fatigue life

This paper introduces a method which allows the calculation of the optimal radial interference and the optimal mandrel shape on a cold-expanded bushing–hole connection commonly used in aerospace structures, in order to obtain the desired values of the residual stresses on the hole surface. This method has been developed by an extended campaign of FE analysis, planned and evaluated with statistical techniques on the basis of a previous presented closed-form method to determine the residual stress field. The method will give the possibility to reduce the zone of the hole surface subject to negligible residual radial stresses, obtaining also compressive residual circumferential stresses on the entire hole surface.An experimental axial fatigue test plan on aeronautical components with optimized cold-expanded bushing–hole connections and subjected to cyclic loads showed a substantial improvement in fatigue life.     

3D Residual Stress Field in Arteries: Novel Inverse Method Based on Optical Full‐field Measurements

Abstract: Arterial tissue consists of multiple structurally important constituents that have individual material properties and associated stress‐free configurations that evolve over time. This gives rise to residual stresses contributing to the homoeostatic state of stress in vivo as well as adaptations to perturbed loads, disease or injury. The existence of residual stresses in an intact but load‐free excised arterial segment suggests compressive and tensile stresses, respectively, in the inner and outer walls. Accordingly, an artery ring springs open into a sector after a radial cut. The measurement of the opening angle is commonly used to deduce the residual stresses, which are the stresses required to close back the ring. The opening angle method provides an average estimate of circumferential residual stresses but it gives no information on local distributions through the thickness and along the axial direction. To address this lack, a new method is proposed in this article to derive maps of residual stresses using an approach based on the contour method. A piece of freshly excised tissue is carefully cut into the specimen, and the local distribution of residual strains and stresses is determined from whole‐body digital image correlation measurements using an inverse approach based on a finite element model.     

Numerical investigation on welding residual stresses in a PWR pressurizer safety/relief nozzle

This paper presents finite element simulation results of residual stresses in dissimilar metal welds of a PWR pressurizer safety/relief nozzle. The present results are believed to be significant in two aspects. The first one is to consider the effect of the presence of similar metal welds on resulting residual stresses. The second one is the mitigation effect of the overlay welding thickness on residual stresses. After dissimilar metal welding, tensile residual stresses are present both at the inner surface and at the outer surface of dissimilar metal welds. Adjacent similar metal welding, however, decreases residual stresses to compressive ones at the inner surface of dissimilar metal welds, possibly due to the bending mechanism caused radial contraction of the weld. At the outer surface of dissimilar metal welds, similar metal welding increases residual stresses. Overlay welding further decreases residual stresses at the inner surface of dissimilar and similar metal welds, but increases slightly residual stresses at the outer surface.     

Vermessung von 3dimensionalen Eigenspannungszuständen an festgewalzten hochfesten Stäben

Measurement of three-dimensional residual stresses at rolled bars with high hardness Bars out of 56 Ni Cr Mo V 7, a diameter of 63 mm and a length of 100 mm were rolled with a force of 12 kN and 27 kN. The hardness of the bars was 2150 N/mm². In 8 different direction along the surface the residual stresses were determined with the help of x-ray diffraction. This was done several times after electrolytic reduction of the material at the measuring zone to get a stress profile in dependence of the depth. Afterwards in two dimensions along the surface and perpendicular to the surface the residual stresses inclusive the shear stresses were determined. High compressive residual stresses were along the surface, but therefore tensile residual stresses were perpendicular to the surface at a zone of around 1.5 mm depth. A comparison of the residual stresses with stresses induced by shot peening is done.     

Oberflächenbehandlung nach spanender Formgebung durch ein einfaches Zusatzverfahren

A supplementary mechanical treatment to strengthen surfaces after machining In this work, a surface treatment is presented in which a hard metal tool insert with rounded edges is pressed on a machined surface at low speed and optimized pressure. This treatment can be executed on the same lathe used previously for machining. The effects on surface topography and surface layer properties (microhardness and X-ray peak halfwidth profiles, as well as residual stresses) have been quantitatively determined. In copper specimens, the surface treatment leads to compressive residual stresses and to strong surface layer deformation and, thus to an increase of near-surface hardness. This effect decreases the amplitude of plastic deformation in the surface layer during fatigue and results in a 25% increase of the fatigue strength at 10⁷ cycles. In Al-2024 T6, the surface treatment causes high compressive residual stresses, an increase in superficial hardness and smoothing of the surface topography. This results in an improvement of the fatigue strength at 10⁷ cycles of 48%.     

梯度陶瓷喷嘴残余应力的有限元分析

为了提高喷嘴的抗冲蚀磨损能力,将梯度功能材料理论运用于喷嘴材料的设计中,改传统的均质喷嘴材料为非均质喷嘴材料,提出在梯度陶瓷喷嘴制备中将残余压应力引入喷嘴入口的设计目标.在组成分布指数一定的条件下,针对主要设计参数对梯度陶瓷喷嘴残余应力的影响进行有限元分析,探讨了梯度层厚度、临界梯度层材料组分差对SiC/(W,Ti)C单梯度陶瓷喷嘴残余热应力的影响规律,在组成分布指数取0.5时,优化SiC/(W,Ti)C梯度陶瓷喷嘴梯度层厚和临界梯度层材料组分差.结果表明,残余应力随梯度层厚h及临界梯度层SiC体积组分差的不同产生很大差异,合理设计梯度层厚h及临界梯度层SiC体积组分差可在喷嘴入口形成有效残余压应力,最佳梯度层厚为5mm,临界梯度层SiC组分差小于5%(体积分数).     

Stable crack growth in a surface compression-strengthened hollow cylinder

In this paper the static fatigue problem for a circumferentially cracked hollow cylinder is examined. For this particular configuration, stable crack growth, in the absense of any external forces, is determined for cylinders with axial components of residual stress which are compressive on the inner and outer radial surfaces and tensile in the cylinder wall. An initial surface crack which is deep enough to penetrate the compression strengthened surface region and enters the tensile zone may propagate in a stable manner until either sudden spontaneous failure occurs or the crack arrests. Since a portion of the crack near the cylinder surface will be closed because of the compressive residual stress field, an additional unknown in the problem is the extent of the crack surface contact. This crack surface contact length is determined by iteration on the integral equation which arises in the mathematical derivation for an embedded circumferential crack in a hollow cylinder. As an illustration of stable crack growth for this geometry with a realistic residual stress distribution, numerical results are presented for a hollow, soda-lime glass cylinder, based on crack growth rates in soda-lime glass exposed to water at 25‡ C. Using the fracture toughness and slow crack growth characteristics for soda-lime glass, the conditions for no crack propagation, crack propagation leading to crack arrest, and catastrophic failure are established.     

An Investigation of Machining-Induced Residual Stresses and Microstructure of Induction-Hardened AISI 4340 Steel

Excessive induction hardening treatment may result in deep-hardened layers, combined with tensile or low compressive residual stresses. This can be detrimental to the performance of mechanical parts. However, a judicious selection of the finishing process that possibly follows the surface treatment may overcome this inconvenience. In this paper, hard machining tests were performed to investigate the residual stresses and microstructure alteration induced by the machining of induction heat-treated AISI 4340 steel (58–60 HRC). The authors demonstrate the capacity of the machining process to enhance the surface integrity of induction heat-treated parts. It is shown how cutting conditions can affect the residual stress distribution and surface microstructure. On the one hand, when the cutting speed increases, the residual stresses tend to become tensile at the surface; and on the other hand, more compressive stresses are induced when the feed rate is increased. A microstructural analysis shows the formation of a thin white layer less than 2 µm and severe plastic deformations beneath the machined surface.     

Residual stresses on flat specimens of different kinds of grey and nodular irons after laser surface remelting

Abstract

Laser surface remelting is one of the best procedures for surface modification of ferrite–pearlite nodular irons. Using this procedure on cast irons it is possible to achieve a very high wear resistance, which can be compared with the wear resistance of surface hardened heat treatable steels. The properties of the modified layer depend on the microstructure before heat treatment and on the amount of energy input transferred into the surface layer of the specimen. The research work has focused on the study of residual stresses after laser surface remelting of different kinds of grey and nodular irons. The identification of residual stresses was performed using the relaxation method, which involved measuring specimen strain. The results of the measured residual stresses confirm that the stresses strongly depend on laser surface remelting conditions. The measurement of residual stresses is very important in exacting dynamically loaded machine parts, which have been subjected to different kinds of heat treatment. In designing parts designers very frequently demand the presence of compressive residual stresses after heat treatment and finish grinding of the surface, since this increases the fatigue strength of the material and reduces the danger of fracture.     

N80钢管残余应力的测试与分析

采用全释放法测试N80钢管的残余应力，结果发现：无论是直管还是发生变形的弯管在它们的同一部位，其内表面与外表面的残余应力是不均匀的，而且沿内圆周或是外圆周其残余应力的分布也不均匀。得出高的残余应力加上分布的不均匀性是钢管发生弯曲变形的主要原因之一。     

Thermal relaxation of residual stresses in shot peened surface layer of (TiB + TiC)/Ti-6Al-4V composite at elevated temperatures

As an effective and important surface treatment method, shot peening can introduce high residual compressive stress and microstructure variation at near surface deformation layers. In this work, residual stresses relaxation behaviors of the shot peened layer of (TiB + TiC)/Ti-6Al-4V composite were investigated during thermal exposure, and the microstrain was calculated according to the integral breadth after isothermal annealing. The microstrain decreased fast and reached the minimum at 500 °C, which resulted from the thermal recovery and dynamic recrystallization. At elevated temperatures, the residual compressive stresses were relaxed in the whole deformation layers, which were caused by the thermally activated gliding of dislocations. The processes of relaxation can be described using a Zener-Wert-Avrami function and the activation energy of the residual stresses relaxation was higher than that of titanium self diffusion, which was ascribed to the hindrance effects of reinforcements as sink sources of dislocations during annealing.     

Analyzing the mechanisms of fatigue crack initiation and propagation in CRH EMU brake discs

A significant number of high-speed electric multiple units’ (EMU) brake discs, manufactured from forged steel, showed thermal cracks during work and NDT. There exist three kinds of cracks on the friction surface; namely, the crackle, radial crack and circumferential crack. Macro-morphologies of the friction surface indicate that the cracks appeared in the interior and edges of the hotspots. Crack growth methods include the single crack propagation and multiple crack connectivity. A finite element analysis (FEA) was performed to determine temperature and stress distribution in the brake disc as well as to estimate stress distribution during braking. Simulation results indicate more significant residual, circumferential tensile stress on the external friction surface after emergency braking. The maximum residual circumferential tensile stress is 200 MPa after 300 km/h emergency braking. In addition, there is only the circumferential compressive stress on a section which is a certain distance from the exterior of the friction surface, and the distance depends on braking conditions. Therefore, not taking into account thickness reduction of the friction surface due to wear, it can be concluded that when the cracks run along the thickness direction to the specified distance, they will cease to run along this direction and begin propagating mainly in the direction of the radius. In addition, based on the simulation results, a measure was presented to prevent and inhibit the crack propagation.