Numerical and experimental analysis of residual stresses for fatigue crack growth

In this paper computational and experimental results are presented concerning residual stress effects on fatigue crack growth in a Compact Tension Shear (CTS) specimen under cyclic mode I loading. For a crack of constant length it is found that hardly any compressive residual stresses or crack closure effects are generated along the crack surfaces behind the crack tip through the considered cyclic mode I loading with a load ratio of R=0.1. Only if fatigue crack growth is modelled during the simulation of the cyclic loading process these well-known effects are found. On the other hand it is shown that they have hardly any influence on the residual stresses ahead of the crack tip and thus on further fatigue crack growth. For all cases considered the computational finite element results agree well with the experimental findings obtained through X-ray diffraction techniques.     

Analysis of residual stresses in particulate reinforced aluminium matrix composite after EDM

This paper reports the effect of properties of three types of particulate reinforced metal matrix composite materials (65?vol.-%SiC/A356·2, 10?vol.-%-SiC–5?vol.-% quartz/Al, 30?vol.-%SiC/A359) and machining parameters on residual stresses induced in the machined surface during powder mixed electric discharge machining. Three electrode materials (Cu, Gr and Cu–Gr) and three machining parameters, namely, peak current and pulse (on/off) duration, are varied to determine the magnitude of induced residual stresses. The result shows that the workpiece, electrode material properties, and pulse off time significantly contribute in the formation of residual stresses. Concentration of reinforced particulates and matrix conductivity also play a vital role in the development of residual stresses. The deposition of disintegrated particles of composite electrode (Cu–Gr) results in high magnitude of residual stresses.     

Numerical predictions and experimental measurements of residual stresses in fatigue crack growth specimens

Controlling macro residual stress fields in a material while preserving a desired microstructure is often a challenging proposition. Processing techniques which induce or reduce residual stresses often also alter microstructural characteristics of the material through thermo-mechanical processes. A novel mechanical technique able to generate controlled residual stresses was developed. The method is based on a pin compression approach, and was used to produce well-controlled magnitudes and distributions of residual stresses in rectangular coupons and compact tension specimens typically used in fatigue crack growth testing. Residual stresses created through this method were first computationally modeled with finite element analysis, and then experimentally reproduced with various levels of pin compression. The magnitudes and distributions of residual stresses in experimental specimens were independently assessed with fracture mechanics methods and good correspondence was found between residual stresses produced using the pin compression and processing techniques. Fatigue crack growth data generated from specimens with low residual stresses, high residual stresses resulting from processing, and high residual stresses introduced through the new pin compression technique were compared and validated. The developed method is proposed to facilitate the acquisition and analysis of fatigue crack growth data generated in residual stresses, validate residual stress corrective models, and verify fatigue crack growth simulations and life predictions in the presence of residual stresses.     

Numerical investigation of through crack behaviour under welding residual stresses

Numerous engineering structures operate under the presence of residual stresses resulting from welding or other manufacturing processes. In the present work, the effect of typical residual stress fields on stress intensity factors and crack propagation angle of cracks developing into the residual stress field under mixed mode loading conditions is studied. For the calculations a numerical methodology based on linear elastic finite element analysis is used. The presented results provide a useful tool for an efficient assessment of the influence of residual stress field on the crack evolution behaviour.     

Numerical simulation of residual stresses in diamond coating on Ti-6Al-4V substrate

In this paper, we present numerical simulations of the residual stresses developed between diamond coatings and Ti-6Al-4V substrates when using chemical vapour deposition technique. The large difference in thermal expansion coefficients of diamond and titanium alloys results in high residual stresses in the diamond film. This could lead to interfacial cracking and material failure. The finite element method was used to simulate the cooling process of diamond films at various thicknesses and deposited at temperatures ranging from 600 °C to 900 °C. The influence of different parameters such as temperature, film thickness, material characteristics, geometry and edge effects are investigated for different case geometries. The film debonding and cracking is discussed and numerical results are compared with existing experimental and numerical results. Finally, some propositions are made to enhance the experimental process in order to reduce the residual stress intensities and the possible material degradation.     

Cold rolling influence on residual stresses evolution in heat-treated AA7xxx T-section panels

This article describes a novel cold working method for relaxing residual stresses in extra-long quenched T-section panels. Distortion led by quench-induced residual stresses in components is usually a great concern for the aviation industry. In this study, the influence of cold rolling on the residual stresses in a scale-down quenched AA7050 T-section specimen is experimentally and numerically investigated. An integrated numerical model was built to predict the quenching and the subsequent cold rolling processes. High levels of compressive stress around the surfaces of quenched T-profile specimens and the tensile surface residual stresses (RS) in the quenched and cold rolled specimens were predicted via numerical analysis, the surface stresses magnitude and distribution have, therefore, been quantified via X-ray diffraction (XRD) technique. The deflection of quenched specimens experienced 1.5% and 3% cold rolling was measured as well. In addition, to examine the cold rolling effect on the mechanical properties of T-profile specimens, hardness tests were carried out on quenched and cold rolled T-section specimens. It concludes that with 1.5% cold rolling the residual stresses in the core part of quenched material can be effectively relieved to an extent of lower than 83 MPa, with limited change for the material properties.     

Fatigue analysis of multipass welded joints considering residual stresses

Gas metal arc welding (GMAW) is one of the most used joining method in the industry. However, one of the main problems of this process is the generation of residual stresses (RS). There are different approaches to predict the fatigue life of welded joints, but in general, these approaches do not consider the real value of RS. Therefore, the current approaches to estimate fatigue life of welded components are conservatives.This paper describes an alternative method to asses high cycle fatigue (HCF) life prediction based on numerically estimated RS values. Results have shown good correspondence for the HCF range, with a maximum average error of 15% in stress for the studied configurations. The proposed method can be used as a valid tool to optimise the geometry of the component and thus decrease the economic cost.     

The effect of residual stresses arising from laser shock peening on fatigue crack growth

Residual stresses have in the past been introduced to manipulate growth rates and shapes of cracks under cyclic loads. Previously, the effectiveness of shot peening in retarding the rate of fatigue crack growth was experimentally studied. It was shown that the compressive residual stresses arising from the shot peening process can affect the rate of crack growth. Laser shock peening can produce a deeper compressive stress field near the surface than shot peening. This advantage makes this technique desirable for the manipulation of crack growth rates. This paper describes an experimental program that was carried out to establish this effect in which steel specimens were partially laser peened and subsequently subjected to cyclic loading to grow fatigue cracks. The residual stress fields generated by the laser shock peening process were measured using the neutron diffraction technique. A state of compressive stress was found near the surface and tensile stresses were measured in the mid-thickness of the specimens. Growth rates of the cracks were observed to be more affected by the tensile core than by the compressive surface stresses.     

Numerical and experimental validation of residual stresses of laser‐welded joints and their influence on the fatigue behaviour

In this work laser‐welded tube‐tube specimens made of aluminium alloys AlMg3.5Mn and AlSi1MgMn T6 were experimentally tested under constant and variable amplitude loading, under pure axial and pure torsion loading. In order to evaluate the influence on fatigue behaviour of the residual stresses, because of the welding process, some specimens were subjected to postweld heat treatment and then were tested. The numerical analyses, using finite element (FE), were carried out to obtain a reliable estimation of the residual stress in the specimen. The numerical results were in a good agreement with experimental ones obtained by means of hole‐drilling method. Finally, the residual stress distribution was superimposed to stress distribution because of fatigue loads obtained by FE analyses applying local concept, to calculate the stresses in the crack initiation zone and to understand the different types of failure that occurred in as‐welded and relieved specimens.     

Numerical modelling and experimental investigation on welding residual stresses in large‐scale tubular K‐joints

This paper is devoted to the experimental and numerical assessment of residual stresses created by welding in the region surrounding the weld toe of tubular K‐shaped joints (i.e. region most sensitive to fatigue cracking). Neutron‐diffraction measurements were carried out on K‐joints cut from large‐scale truss beams previously subjected to high cycle fatigue. Tri‐axial residual stresses in the transverse, longitudinal and radial direction were obtained from the weld toe as a function of the depth in the thickness of the tube wall. In addition, thermomechanical analyses were performed in three‐dimensional using ABAQUS and MORFEO finite element codes. Experimental and numerical results show that, at and near the weld‐toe surface, the highest residual stresses are critically oriented perpendicularly to the weld direction, and combined with the highest externally applied stresses. Based on a systematic study on geometric parameters, analytical residual stress distribution equations with depth are proposed.     

Numerical evaluation of temperature fields and residual stresses in butt weld joints and comparison with experimental measurements

This paper presents a novel numerical model, based on the finite element (FE) method, for the simulation of a welding process aimed to make a two‐pass V‐groove butt joint, paying attention on the prediction of residual stresses and distortions. The ‘element birth and death’ technique for the simulation of the weld filler supply has been considered within this paper. The main advancements with respect to the state of the art herein proposed concern: (i) the development of a modelling technique able to simulate the plates interaction during the welding operation when an only plate is modelled. This phenomenon is usually neglected in literature; (ii) the heat amount is supplied to the FEs as volumetric generation of the internal energy, allowing overcoming the time‐consuming calibration phase needed to use the Goldak's model, commonly adopted in literature. Predicted results showed a good agreement with experimental ones.     

Finite element analysis of the effects of comers on residual stresses in protective oxide scales

Finite element simulations are used to examine residual thermal stresses and strains in corner regions of protective Al₂O₃ scales on Fe₃Al specimens, both during cooling from oxide formation temperatures and during subsequent thermal cycling. The effects of a corner's radius of curvature and oxide thickness, as well as the impact of aluminide plasticity, are considered. Localized plasticity is found to have a major influence on net deformation and on the magnitude and location of maximum stress. As the ratio of corner curvature to oxide thickness (r_s/t) is reduced, stresses within the oxide corner shift from highly compressive to tensile and the location of the maximum principal stress moves from the substrate to the oxide scale. Based on these stress distributions prior to the development of any flaws, key implications about the tendencies for damage are addressed. The stress evolution during cooling and thermal cycling is presented; these results demonstrate the effects of temperature-dependent material properties. For the material behavior assumed in this study, thermal cycling does not cause significant stress relaxation.     

An experimental and numerical study on adhesive joints for composites

In many composites structures the use of joints allows not only more versatility during the assemblage process but also reduces the cost during the manufacturing. As joints are considered regions of weakness, their study has been conducted since late 1930s. Researchers have been working on new joint designs looking for better performances. One of these new designs is the bonded wavy-lap joint presented by Zeng and Sun in 2001. This paper addresses the advantages and disadvantages of the wavy-lap joint and a modified wavy-lap joint design is studied. To be able to guarantee the data consistency a statistical study is performed considering not only the sample size population but also the statistical differences between the single-lap and wavy-lap joints. Besides, the experimental tests, a finite element simulation is carried out to analyze the stress fields inside the joints. The results show an average increase on loading to failure close to 41%. This fact could be due to the compressive stress field developed inside the wavy-lap joint. In addition, this stress field distribution can also be the reason for the adherent delamination observed on the wavy-lap joints. So far, the modified wavy-lap joint seems to lead to stronger joints.     

A simple but effective FE model with plastic shot for evaluation of peening residual stress and its experimental validation

We propose a practical finite element (FE) model for evaluation of peening residual stress. The model aims to produce a solution approaching the endeavored 3D FE solution. We investigate the effect of physical factors including material damping, dynamic friction and strain rate. The kinematical factors including shot diameter and impact velocity are also considered. Integrating those factors and plastic shots, we set up an effective FE model. Based on the arc height and coverage matching with the Almen saturation curve, impact velocity needed for FE analysis is determined. The model is found to provide the solution comparable with the 3D multi-impact FE solution and the experimental XRD result.     

Effects of welding speed on the multiscale residual stresses in frictionstir welded metal matrix composites

The effects of welding speed on the macroscopic and microscopic residual stresses(RSes) in friction stir welded 17 vol.% SiCp/2009 Al-T4 composite plates were studied via neutron diffraction and an improved decoupled hierarchical multiscale modeling methods. Measurements showed that the macroscopic and total RSes had the largest variations in the longitudinal direction(LD). Increasing the welding speed led to higher values of measured LD macroscopic and total RSes in the matrix. The welding speed also significantly influenced the distributions and magnitudes of the microscopic RSes. The RSes were predicted via an improved hierarchical multiscale model, which includes a constant coefficient of friction based thermal model. The RSes in the composite plates before friction stir welding(FSW) were computed and then set as the initial states of the FSW process during modeling. This improved decoupled multiscale model provided improved predictions of the temperature and RSes compared with our previous model.     

Influence of thermal residual stresses on the composite macroscopic behavior

The influence of the thermal residual stress on the deformation behavior of a composite has been analyzed with a new micromechanical method. The method is based on secant moduli approximation and a new homogenized effective stress to characterize the plastic state of the matrix. It is found that the generated thermal residual stresses after cooling and their influence on the subsequent deformation behavior depends significantly on the aspect ratio of the inclusions. With prolate inclusions, the presence of thermal residual stresses generate a higher compressive hardening curves of the composite, but it is reversed with oblate inclusions. For particle reinforced composite, thermal residual stresses induce a tensile hardening curve higher than the compressive one and this is in agreement with experimental observations.     

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.     

Texture development and residual stress in UHV evaporated silver films on glass substrates as a function of substrate temperature

Pole figures were collected for silver films of 140 nm thickness deposited on glass substrates with deposition rate of 0.076 nm s⁻¹, for substrate temperatures between 300 and 600 K covering all three zones in the structure zone model (SZM), using an X-ray diffractometer in texture mode. Additional information for determination of residual stress in these films was obtained by the technique. The components of the stress tensor were obtained using measurements at three different φ angles of 0°, 45° and 90°. The crystallite sizes as a function of substrate temperature and ψ angle were also obtained, and showed, an increase with substrate temperature in agreement with the SZM predictions, and a decrease with ψ angle, possibly due to some correlation between the preferred orientation and grain size. The relation between stress in these films and the processes of film growth in the SZM is discussed.     

Residual stresses in steel rod with collar formed by partial diameter-enlarging technique

Residual stress distribution in a carbon steel component with collar manufactured by partial diameter-enlarging (PDE) process was evaluated using the angular dispersion and time-of-flight neutron diffraction methods in the interior and X-ray diffraction method at the surface of the collar. The residual stresses in the PDE specimen were smaller compared with those of a specimen with the similar shape and dimension made by a simple compression (SC) process. The hoop residual stress varied from ?98 to 2?MPa around the circumference at the surface of the collar in the PDE specimen, whereas it was nearly constant in the SC one. The residual stresses in the central region of the both specimens were nearly in a hydrostatic compressive stress condition.     

Theoretical and experimental determination of residual stresses in plane joints

We have developed a mathematical model for determining residual stresses and stress concentration in the neighborhood of a plane joint of dissimilar materials and formulated variational statements of direct and inverse problems. The parameters of the stress–strain state of the object under study measured by nondestructive methods serve as input data for the inverse problem. We carry out a numerical analysis of solutions of the direct and inverse problems of determining stress concentration in the neighborhood of a joint of materials with different moduli. Finally, we discuss the applicability of the developed approach to the monitoring of the stress–strain state of joints in the course of their operation and to the evaluation of their residual life.