A technique for dynamic tensile testing of metals

A technique is described for obtaining full dynamic stress/strain curves in tension up to strain rates of 100^s-1. In conjunction with a high speed servo-hydraulic machine, a low inertia extensometer has been developed to facilitate measurement of specimen tensile strain up to fracture.
The benefits of the technique are highlighted in relation to currently available methods for dynamic stress/strain measurement.     

Ultrasonic Instrumentation for Measuring Applied Stress on Bridges

The measurement of applied stress on bridges can provide valuable information on the condition of the structure. The conventional technique for measuring applied stress is with a strain gage. However, strain gages can be time consuming to install because first the surface must usually be prepared. On a bridge, paint removal will most likely be necessary as part of this surface preparation. When dealing with lead-based paints, which are considered hazardous waste, many time consuming removal procedures are required. Because of these factors, a device that measures applied stress without requiring paint removal could be useful. While a “clamp-on” strain gage can also be used to measure applied stress without requiring paint removal, this type of strain gage can not be used on some bridge details, such as webs of I-beams and tops of box girders. An ultrasonic technique using non-contact electromagnetic transducers provides a possible method for applied stress measurement which is not limited by the same factors as those with conventional strain gages. The transducers operate through nonconductive and conductive (lead-based) paint and work on rusted, pitted surfaces. Our previous research developed a technique for measuring applied stresses on bridges with EMATs and included many laboratory tests. This paper describes field applications of the technique on actual bridge structures, as well as additional system testing and instrument calibration in the laboratory.     

Measurement of residual stresses in a multi-layer explosive welded joint with successive milling technique

In the multi-layer welded joint of titanium-tantalum (Ti-5Ta/Ti-5Ta/Ta/substrate of stainless steel (SUS304) the second layer of plate Ti-5Ta is 4mm thick, and the third plate Ta is only 1 mm thick. It is almost impossible to measure the stresses near the weld with cutting strip technique. Using a successive milling technique the inplane elastic strain releases normal to the thickness direction are measured. With the finite element method (FEM) inherent strain distribution along thickness z-direction is evaluated according to the elastic strain releases. Subsequently, assuming that the inherent strains (plastic strains resulting from the welding process) are the initial strains of the FEM analysis for the welded residual stresses, these are used further to evaluate the residual stress distributions along the thickness z-direction in the multi-layer explosive welding joint.     

压痕应变法测量残余应力的不确定度分析

压痕应变法是近期出现的一种非常有价值的(焊接)残余应力测量技术,它具有无损、快捷、精确、成本低等特点。采用该技术测量残余应力时的误差大小或不确定度分析是人们关注的问题之一。应用B类评定法对采用该技术测量Q345低合金钢中焊接残余应力的不确定度进行了详尽分析,结果表明,应力相对不确定度的大小主要决定于应变的绝对值,低应变情况下的相对不确定度主要由重复性试验的应变不确定度决定。一般情况下,应力的标准不确定度数值为20～30MPa。     

考虑应变率影响的厚壁筒残余应力场分析

本文针对弹塑性拉压循环加卸载条件下，不同的应变率（１０－４－１０－２ｓ－１）变化，对高强钢（ＰＣｒＮｉ３ＭｏＶ）材料的屈服应力、应变硬化参数和反向屈服应力等参量的影响进行了实验研究，提出了便于理论计算的简化弹塑性本构模型，并假设拉屈服应力与压屈服应力的差值不随应变率的不同而发生变化，这一假定与实验结果相符合，且便于工程计算。针对厚壁筒自紧加工工艺的残余应力场分析问题，用本文提出的模型对厚壁筒在四种不同的应变率条件下进行自紧加工时残余应力场的变化及不同的自紧效果进行了详细的分析和比较，并提出了改进工艺过程和提高自紧效果的建设性意见。     

A new approach to triaxial residual stress evaluation by the hole drilling method

A new analysis technique is introduced to resolve the triaxial residual stress profiles from measurements using the conventional strain gauges for the hole drilling or ring core method extended with a displacement transducer to measure the out of plane displacement. The new technique uses an inverse formulation with wavelets.     

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

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.     

云纹干涉法测定复合材料单孔连接件的应力场

本研究首次将云纹干涉法应用于复合材料单销钉连接件位移场的测量。从位移的云纹图用位移导数法求得销钉孔中心水平截面上的应变。根据复合材料层合板的直法线假设和层合板的折算刚度矩阵算出截面的平均应力分布。通过静力平衡,所得误差在6%以内。本研究结果证实,云纹干涉法测量复合材料连接件的应变场和应力场是有效的实验方法。      

Development and comparison of residual stress measurement on welds by various methods

Abstract

Residual stress constitutes an integral part of the total stress acting on any component in service. It is imperative to determine residual stress to estimate the life of critical engineering components, especially those that are welded. The stresses caused by non-uniform temperature distribution due to welding and the effect of these multiaxial stresses upon service performance are discussed. A controlled thermal severity test (CTS) was performed on mild steel plates bolted together, with anchor welds deposited on opposite sides. After cooling, bithermal and trithermal test welds were deposited one after the other. Varying welding stresses were deliberately introduced by using different thicknesses of both plates to change the thermal severity numbers (TSN). The main experimental technique used here to determine the magnitude and nature of residual stress is based on X-ray diffraction (XRD). It was utilised to develop and standardise other techniques. The XRD method is based on the peak shiftin the diffraction profile due to the presence of stress using a sin² ψ method. The peak shift is determined by orienting the sample at different angles ± ψ to the incident X-ray beam. The semidestructive technique of hole drilling and use of a strain gauge was also employed to determine residual stress in CTS specimens. The magnitude, nature, and direction of principal stresses were determined by relieving stresses through incremental blind hole drilling and measuring strain values at each step. The surface displacements arising due to hole drilling can also be determined by laser holography. A sandwich holography technique was developed to avoid unwanted rigid body motions of samples due to hole drilling when relieving stresses. Stress values were obtained by measuring fringe displacement between two exposures of a sandwich hologram, due to hole drilling. Results on the change in residual stress values with TSN are discussed. The residual stress values determined by XRD and sandwich holography were found to be comparable, and stress values obtained by hole drilling/strain gauge measurement were higher than these values. The reasons are discussed.     

Cyclic response and inelastic strain energy in low cycle fatigue

The cyclic response of ASTM A-516 Gr 70 carbon low alloy steel subjected to fully-reversed constant strain- or stress-controlled cycles has been determined. The cyclic stress/strain relationship of the material was obtained through a least squares fit technique.Stable hysteresis loops at half life for various strain ranges are presented. The material does not exhibit Masing-type behaviour. The total inelastic strain energy is calculated by a new method and is in good agreement with the measured values. Comparison is also made with other proposed relationships. The total strain energy dissipated at failure may be expressed as W_f = KN_f^α     

Comparison of techniques for residual stress determination in a bead on plate titanium sample

Residual stress determination has been carried out on production welds to provide engineering data.
A parting out technique has been used in which a strain gauged through thickness slug of material is removed from the weld area.
The centre hole technique has been used with the blind hole in the weld material.
There were differences between the results from the two techniques and a fully penetrant bead on plate fatigue sample with the bead running axially was used in order to compare the two techniques in more detail.
After parting out, the layer removal technique was carried out in order to provide a relatively detailed through thickness residual stress distribution in order to explain the differences between the results from the centre hole and parting out techniques.     

Mode III Interlaminar Fracture Behavior of Glass Fiber Reinforced Polymer Woven Laminates at 293 to 4 K

This paper deals with mode III delamination properties of glass fiber reinforced polymer woven laminates at room temperature (293 K), liquid nitrogen temperature (77 K), gas helium temperature (20 K), and liquid helium temperature (4 K). In order to evaluate these properties, the Split Cantilever Beam (SCB) fracture test is performed. The load is applied to a test specimen through a set of identical grips in order to reduce (in some degree) the mode II loading at the free edges. A three-dimensional finite element analysis is used to study the stress and strain state of the specimens and to interpret the experimental measurements. The strain energy release rate is calculated by using the virtual crack closure technique. It is found that the strain energy release rate is dominated by the mode III component. A non-uniform distribution of the strain energy release rate along the delamination front is obtained with mode III component having maximum at the center of the delamination front, while mode II component increases towards the free edges. The strain energy release rate is also determined using the crack closure technique. A finite element analysis is also carried out to calculate the stress intensity factors for the SCB specimens. The fracture surfaces are examined by scanning electron microscopy to identify the fracture mechanisms. The most important conclusion from the present study is that at temperature lowering from 293 to 20 K the mode III fracture toughness increases, further cooling to 4 K produces a toughness decrease.     

A Method of Measuring Through‐Thickness Internal Strains and Stresses in Graphite

Abstract: Currently, the structural integrity of the nuclear graphite reactor components is evaluated using irradiated material properties data obtained from test reactors. These data are applied to numerical or mathematical models to assess the integrity of the graphite components. On the other hand, there is a need to measure internal strains and stresses in reactor core graphite and to explore the potential for in‐situ measurement. The deep hole drilling (DHD) technique is a semi‐destructive method for measurement of the through thickness residual strains or stresses. Previously the technique has been applied successfully to metallic and composite materials. In this paper, the method for internal strain and stress measurement in polygranular graphite is examined particularly when a significant volume fraction of porosity is present. Finite element simulation shows that the method can be used to measure internal stresses generated by a thermal gradient. On the basis of this a series of experiments have been conducted using Pile Grade ‘A’ (PGA) and PG25 filter graphite; with the latter being a surrogate for service exposed material. Tests were conducted to illustrate that the bulk mechanical response was linear elastic for both graphites and elastic moduli were measured. The DHD method was then used to determine internal strain and stress profiles through the materials. The results were compared with the strain data obtained from strain gauges bonded to the samples. Overall, there was an excellent agreement between the measured through‐thickness internal strains and stresses and the surface strains and stresses determined from the applied loading.     

Entire Life Time Monitoring of Filament Wound Composite Cylinders Using Bragg Grating Sensors: II. Process Monitoring

This article is the second of a series of three papers concerning monitoring of filament wound cylinders using Bragg gratings. In this second part, the tooling presented in Part I is used to embed gratings and thermocouples in filament wound glass reinforced epoxy composite cylinders during fabrication. Bragg grating strain was obtained from wavelength and temperature response, by a calibration technique described here. Results from tests on five cylinders show the Bragg grating’s capability to monitor strain evolution during fabrication, and the capacity to detect several phenomena occurring during cure is established, in addition to quantifying the initial material condition of the cylinder before it enters service.     

Extended finite element method coupled with face‐based strain smoothing technique for three‐dimensional fracture problems

In this work, the extended finite element method (XFEM) is for the first time coupled with face‐based strain‐smoothing technique to solve three‐dimensional fracture problems. This proposed method, which is called face‐based smoothed XFEM here, is expected to combine both the advantages of XFEM and strain‐smoothing technique. In XFEM, arbitrary crack geometry can be modeled and crack advance can be simulated without remeshing. Strain‐smoothing technique can eliminate the integration of singular term over the volume around the crack front, thanks to the transformation of volume integration into area integration. Special smoothing scheme is implemented in the crack front smoothing domain. Three examples are presented to test the accuracy, efficiency, and convergence rate of the face‐based smoothed XFEM. From the results, it is clear that smoothing technique can improve the performance of XFEM for three‐dimensional fracture problems. Copyright © 2015 John Wiley & Sons, Ltd.     

The determination of post yield stresses from strains measured on strain hardening materials

The paper examines the computational techniques of Mendelson¹ and that proposed by Moreton-Moffat² to derive post yield stresses from strain gauge readings and compares them with the fundamental Prandtl-Reuss approach. Although the approach by Mendelson is extensively used in one form or another in elasto-plastic analysis its application in the experimental stress analysis field is less common. Moreton-Moffat highlighted this application and modified Mendelson's method claiming that it was unnecessary to use the post yield constitutive law. In this latter respect their approach is shown in general to be inadequate. The technique based on the Mendelson approach¹ is found to be an accurate and useful solution especially when modified to incorporate the slope of the constitutive law at the mean stress of any particular finite step. Although the method is an approximate strain analogue of the Prandtl-Reuss equations the approximation is excellent for practical step sizes.     

Effects of the machining conditions on the strain hardening and the residual stresses at the roots of screw threads

The strain hardening and the formation of the residual stresses at the roots of threaded joints produced by machining according to American Petroleum Institute (API) standards was investigated. Initially the problem is defined and then an experimental technique was developed for measuring the residual stresses at the roots of fine screw threads. The screw thread was cut on a tubular bar from chromium–nickel based alloyed steel. Residual stresses were measured by the electro-chemical layer removal technique. Experimental work showed that, sever strain hardening and the concentration of residual stresses at the roots of the screw threads took place depending on the machining conditions. Strain hardening in the range of 320–430 HV were found on the screw thread surfaces as compared to the base hardness of 260 HV. Residual stress ranging from 600 to 1450 MPa was developed as compared to the material tensile strength of 850 MPa. The depth for maximum residual stress is around 20 μm.     

新型含铝奥氏体耐热合金Fe-20Cr-30Ni-0.6Nb-2Al-Mo的动态再结晶行为

在Gleeble-3500热力模拟试验机上对一种新型奥氏体耐热合金(Fe-20Cr-30Ni-0.6Nb-2Al-Mo)进行单道次热压缩实验,结合OM、EBSD及TEM等表征手段,研究了该合金在950~1 100℃和0.01~1s-1热变形参数下的动态再结晶行为,采用回归法确定了合金的热变形激活能和表观应力指数,并以此构建其高温本构模型。实验结果表明,新型奥氏体耐热合金的应力水平随变形温度的升高而降低,随应变速率的增大而升高;动态再结晶行为更易发生在较高变形温度或较低应变速率下。采用lnθ-ε曲线的三次多项式拟合求解临界再结晶拐点的方法,较准确地预测了合金的动态再结晶临界点。此外,归纳出该合金在动态再结晶过程中的形核机制,主要包括应变诱导晶界迁移、晶粒碎化以及亚晶的合并。     

Fracture mechanics solutions to spot welds

Notch stress, stress intensity factors and J-integral at a spot weld are generally expressed by structural stresses around the spot weld. The determination of these parameters are then simplified as determining the structural stresses that can be calculated by a spoke pattern in finite element analysis. Approximate stress formulas for structural stress, notch stress and equivalent stress intensity factor are given for common spot-welded specimens. With the aid of the formulas, test data in terms of the original load can be easily transformed into the data in terms of the structural stress, notch stress or equivalent stress intensity factor at the spot weld. The formulas also facilitate the transfer of test data across different specimens. A measuring method is given for lap joints. The strain gauge technique developed for the tensile-shear specimen shows that all the structural stress, notch stress, stress intensity factors and J-integral at the spot weld can be determined by two strain gauges attached only to the outer surface of one sheet. The results presented here should be helpful for the analysis and testing of spot welds and for developing measuring methods for spot welds.     

基于应力超收敛恢复技术的广义特征值问题后验误差估计

根据有限元解的超收敛特性提出了一种基于应力超收敛恢复技术的广义特征值问题后验误差估计。通过对单元内的应力超收敛点以及相邻单元的应力超收敛点进行插值或外推处理,得到单元内其它点处更高精度的应力解。通过高精度的应力值可以得到结构处理后改进的势能。将改进的势能代入瑞利商,最终得到比原始有限元解更高精度的特征解。将后处理特征解作为“准精确解”代替误差估计因子中未知的精确解,实现后验误差估计过程。数值计算结果表明,所提出的后验误差估计是渐进精确的,因此可作为结构广义特征值问题自适应有限元方法的误差估计因子。