Influence of residual stresses in the performance of cold-drawn pearlitic wires

The mechanical properties of cold-drawn pearlitic wires are controlled largely by the microstructure developed during processing and, to some extent, by the residual stresses during drawing. The advent of powerful computers and the availability of equipment to perform diffraction experiments, have made possible numerical predictions and accurate measurements of residual stresses. This paper—a review of work done by the author and collaborators—shows how stress-relaxation losses, environmental assisted cracking and fatigue life of cold-drawn pearlitic wires are influenced by residual stresses. The role of pre-stretching loads, or of stress relieving treatments, on stress-relaxation can be understood when the profile of residual stresses is known. Some awkward results in times to fracture during hydrogen embrittlement tests can be explained if accurate values of residual stresses near the surface are known, and the same is true of fatigue life. In this context numerical simulations and measurements performed on cold-drawn pearlitic wires, with different profiles of residual stresses, have shown very good quantitative agreement.     

A three dimensional model for direct laser metal powder deposition and rapid prototyping

A three-dimensional model for direct laser metal powder deposition process and rapid prototyping is developed. Both numerical and analytical models are addressed. In the case of numerical modeling, the capabilities of ANSYS parametric design language were employed. The model calculates transient temperature profiles, dimensions of the fusion zone and residual stresses. Model simulations are compared with experimental results acquired on line using an ultra-high shutter speed camera which is able to acquire well-contrasted images of the molten pool, and off-line using metallographical and x-ray diffraction analyses. The experiments showed good agreement with the modeling. The results are discussed to provide suggestions for feedback control and reduction of residual stresses.     

Effect of welding parameters on residual stresses in dissimilar joint of stainless steel to carbon steel

In this study, a thermo-mechanical model was utilized to investigate the effects of welding parameters on the distribution of residual stresses in dissimilar TIG welds of low carbon and ferritic stainless steels. To solve the governing thermal and mechanical problems, a finite element program, ANSYS, was employed while the different aspects such as welding sequence and dilution were considered in the numerical solution. To validate the predictions, the model results were compared with the residual stresses measured by X-ray diffraction technique and a reasonable agreement was found. The results show that the magnitude of tensile residual stresses decrease as the welding current increases while lower residual stresses are produced in the longer samples. In addition, the magnitudes of residual stresses significantly decrease when a symmetric welding sequence is employed especially for the carbon steel part with the higher yield strength.     

Experimental and finite element predictions of residual stresses due to orthogonal metal cutting

The development and implementation of a finite element method for the simulation of plane-strain orthogonal metal cutting processes with continuous chip formation are presented. Experimental procedures for orthogonal metal cutting and measurement of distributions of residual stresses using the X-ray diffraction method are also presented. A four-node, eight degree-of-freedom, quadrilateral plane-strain finite element is formulated. The effects of elasticity, viscoplasticity, temperature, friction, strain-rate and large strain are included in this formulation. Some special techniques for the finite element simulation of metal cutting processes, such as element separation and mesh rezoning, are used to enhance the computational accuracy and efficiency. The orthogonal metal cutting experiment is set-up on a shaper, and the distributions of residual stresses of the annealed 1020 carbon steel sample are measured using the X-ray diffraction method. Under nominally the same cutting conditions as the experiment, the cutting processes are also simulated using the finite element method. Comparisons of the experimental and finite element results for the distributions of residual stresses indicate a fairly reasonable level of agreement. The versatility of the present finite element simulation method allows for displaying detailed results and knowledge generated by orthogonal metal cutting processes, such as the distribution of temperature, yield stress, effective stress, plastic strain, plastic strain-rate, hydrostatic stress, deformed configuration, etc. Such knowledge is useful to provide physical insights into the process as well as to better design the process for machining parts with improved performance.     

Modelling and Statistical Treatment of Residual Stress Distributions in an Edge Welded Stainless Steel Beam

Abstract: Experimental, finite element analysis and statistical studies of residual stresses in edge welded type 316H stainless steel beams are presented. The experimental stress measurements were previously performed by different laboratories using neutron and synchrotron X‐ray diffraction. An analytical model to describe the magnitude and distribution of the residual stresses is presented. Results from finite element analyses are also provided. It is found that there is general agreement between the trends in the residual stresses derived from analysis and measurement. However, the scatter in results is substantial and a statistical framework for treating residual stresses using Bayesian statistics based on experimental and simulation results is described. The Bayesian analytical approach that uses the analytical model as a reference permits the model to be applied to circumstances outside the experimental conditions.     

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

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.     

Cold drawn steel wires—processing, residual stresses and ductility Part II: Synchrotron and neutron diffraction

Cold drawing of steel wires leads to an increase of their mechanical strength and to a drop in their ductility. The increase of their mechanical strength has long been related to the reduction of the various material scales by an intense plastic deformation. Besides, it was discussed in the companion paper that large plastic deformation leads to the loss of the material hardening capabilities and that, in such a case, residual stresses preserve the elongation to failure of wires. Experimental measurements of residual stresses inside the wire have therefore been undertaken. In this paper, lattice parameters as measured using synchrotron diffraction are compared with those calculated using the residual stress fields as determined by the finite‐element method. There is a major disagreement between experimental and numerical results that is too large to be attributed to the errors of the finite‐element analyses. Therefore, neutron diffraction experiments have also been performed. These measurements show that there is a significant variation of the lattice parameter with the drawing level, which is not inherited from residual stresses, and that variation is very sensitive to the cooling rate after processing. It is therefore proposed that cold drawing would induce a phase transformation of the steel, possibly a martensitic transformation.     

X射线衍射法测残余应力的“突变”现象与定峰技巧探讨

X射线衍射法（XRD）是一种常用的测试金属表面残余应力的无损检测法。依据X射线应力测试的原理,对试验中遇到的衍射强度“突变”现象进行了初步探讨,并对其产生的原因和定峰中的处理方法进行了具体分析,为进一步发展和完善铝合金焊接残余应力的X射线分析技术提供了参考。     

Combined experimental–numerical study on residual stresses induced by a single impact as elementary process of mechanical peening

Peening processes can be used as a fatigue enhancement treatment for metallic structures by locally introducing compressive residual stresses. A combined experimental–numerical study on a single-impact process with a drop tower on the aluminium alloy AA5754, representing the elementary process of mechanical peening, has been performed to investigate different impact parameters on the residual stress profile. Residual stresses have been measured using high-energy X-Ray diffraction. A three-dimensional finite element model is used to predict the residual stresses numerically. The elastic strain components from the numerical results are used to calculate residual stresses by assuming either a plane stress or a plane strain state for different specimen thickness to assess the validity of respective assumption. The validity of the numerical simulation is evaluated based on comparisons of the elastic strain profiles and the percentage loss in kinetic energy of the steel ball due to the impact for four different energies, showing overall a good agreement in the experimental–numerical comparisons.     

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

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.     

Finite element analysis of laser shock peening of 2050-T8 aluminum alloy

Laser shock processing is a recently developed surface treatment designed to improve the mechanical properties and fatigue performance of materials, by inducing a deep compressive residual stress field. The purpose of this work is to investigate the residual stress distribution induced by laser shock processing in a 2050-T8 aeronautical aluminium alloy with both X-ray diffraction measurements and 3D finite element simulation. The method of X-ray diffraction is extensively used to characterize the crystallographic texture and the residual stress crystalline materials at different scales (macroscopic, mesoscopic and microscopic).Shock loading and materials’ dynamic response are experimentally analysed using Doppler velocimetry in order to use adequate data for the simulation. Then systematic experience versus simulation comparisons are addressed, considering first a single impact loading, and in a second step the laser shock processing treatment of an extended area, with a specific focus on impact overlap. Experimental and numerical results indicate a residual stress anisotropy, and a better surface stress homogeneity with an increase of impact overlap.A correct agreement is globally shown between experimental and simulated residual stress values, even if simulations provide us with local stress values whereas X-ray diffraction determinations give averaged residual stresses.     

EFFECT OF RESIDUAL STRESSES OF SHOT PEENING ON THE FATIGUE BEHAVIOUR OF A HIGH STRENGTH STEEL*

Abstract— The effects of shot-peening residual stresses on bending fatigue behaviour of welded plate and surface-flawed plate were investigated. The results show that shot peening residual stresses may significantly increase fatigue strength as well as the threshold stress- intensity factor range of a surface-flawed plate. This paper presents a simple analytical method for determining the residual stresses. The calculated values are essentially in agreement with the experimental results.     

Generation of residual stress and plastic strain in a fracture mechanics specimen to study the formation of creep damage in type 316 stainless steel

Residual stresses are created in type 316H stainless steel fracture mechanics specimens using the process of local out‐of‐plane compression (LOPC). Three sets of LOPC tools are used to create different distributions of residual stress near to the crack tip. Also the tools create different levels of prior plastic strain. Residual stresses are measured using the neutron diffraction method and compared with the stress predictions obtained from finite element (FE) simulations of LOPC. The specimens are then subjected to thermal exposure at 550 °C for several thousand hours. A creep deformation and damage model is introduced into the FE analysis to predict the relaxation of stresses and creation of damage in the specimens. Neutron diffraction experiments are undertaken to measure the relaxed residual stresses and fractographic analysis of thermally exposed samples measured the extent of creep damage. A comparison between measured and simulated results demonstrates that the prior plastic strain has a significant effect on damage accumulation but this is not accounted for in the current creep damage models.     

Residual stresses of sputtering titanium thin films at various substrate temperatures

This work seeks to characterize the residual stresses of titanium thin films as they are affected by various substrate temperatures during the sputtering process. The titanium thin films are deposited on silicon wafers by a RF magnetron sputter while different substrate temperatures are considered. The residual stresses are measured by both X-ray diffraction and a substrate curvature method, and consistent results are obtained by both methods. The results show that the residual stress decreases as the substrate temperature increases, in which the stress changes from tensile to compressive when the substrate temperature increases from 25 to 50 degrees C. Furthermore, the elastic modulus and hardness of the titanium thin films are tested with a nanoindenter using a standard Berkovich probe. Correlations between the residual stresses and mechanical properties measured by nanoindentation are also discussed.     

Thermal Residual Stresses in W Fibers/Zr-based Metallic Glass Composites by High-energy Synchrotron X-ray Diffraction

Thermal residual stresses in W fibers/Zr-based metallic glass composites were measured by in situ high energy synchrotron X-ray diffraction(HEXRD). The W fibers for the composites were 300,500,and 700 m m in diameter,respectively. Coaxial cylinder model(CCM) and finite element model(FEM) were employed to simulate the distribution of thermal residual stress,respectively. HEXRD results showed that the selected diameters of W fiber had little influence on the value of thermal residual stresses in the present composites. Thermal residual stresses simulated by CCM and FEM were in good agreement with HEXRD measured results. In addition,FEM results exhibited that thermal residual stress concentrated on interface between the two phases and area where the two W fibers were the closest ones to each other.     

喷丸起落架外筒焊接热影响区的残余应力测定

本文用X射线法测定了喷丸起落架外筒焊缝影响区的残余应力,并从残余应力角度考察了起落架外筒现行工艺路线的优劣。测定结果表明,在相同构件上虽然所测方向和部位不同,但残余应力的分布、大小及符号基本相同。与前起外筒相比,喷丸处理在主起外筒上形成的残余压应力值较低。分析认为消除焊接残余拉应力的合理工序,是两种外筒均应采用焊后热处理,但应防止表面脱碳。     

Residual stress of as-deposited and rolled wire+arc additive manufacturing Ti–6Al–4V components

Wire + arc additive manufacturing components contain significant residual stresses, which manifest in distortion. High-pressure rolling was applied to each layer of a linear Ti–6Al–4V wire + arc additive manufacturing component in between deposition passes. In rolled specimens, out-of-plane distortion was more than halved; a change in the deposits' geometry due to plastic deformation was observed and process repeatability was increased. The Contour method of residual stresses measurements showed that although the specimens still exhibited tensile stresses (up to 500?MPa), their magnitude was reduced by 60%, particularly at the interface between deposit and substrate. The results were validated with neutron diffraction measurements, which were in good agreement away from the baseplate.

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

受压缺陷矩形板振动分析

采用简易高效的方法分析受压缺陷矩形板的振动问题。首先应用奇异摄动理论计算受压缺陷板的后屈曲,然后给出后屈曲平衡路径上的微振动方程,计算振动频率,提出了受压缺陷板振动频率和轴压、残余应力与残余变形关系的一个显式表达式。探讨了焊接残余变形、残余应力对矩形板振动频率的影响。最后给出了计算实例,并与试验结果进行了比较。     

Evaluation of Residual Stresses Using Laser-Generated SAWs on Surface of Laser-Welding Plates

In this paper, residual stresses in laser-welding plates are studied by both numerical simulation and experiment based on laser ultrasonics. First, a three-dimensional finite-element model is developed to predict temperature distributions and thermo-structure response during the laser-welding process of an aluminum alloy plate, and the residual stresses around the joint are described from structure analysis. After that, experiments based on surface acoustic waves generated by a pulsed laser are carried out to determine the velocity distribution of SAWs around the joint, from which the distribution of main residual stresses are calculated according to acoustoelastic theory. By comparing the thermal-structure model results with the measurements, it is found that the numerical simulation results are in good agreement with the experimental data.     

Residual stress measurement in AlSi alloys

In this work, the relaxation of residual stresses inside a sample made of the aluminum alloy AlSi7Mg0.3 after tempering is described. The comparison of stress evaluation by X‐ray diffraction and incremental hole drilling method combined with electronic speckle pattern interferometry strain determination gives the opportunity to evaluate micro stresses together with first order macro stresses. Compressive stresses within the surface of a cold worked sample are relaxed by tempering. The X‐ray diffraction evaluation is supported by the analysis of a stress‐free sample through incremental hole drilling method.