Estimation of bending of micromachined gold cantilever due to residual stress

Electroplated gold is widely used as the material for the micromachined beam structures due to its excellent electrical and mechanical properties. This work attempts to analyze the surface micromachined gold cantilever beams under inherently present stress gradient. The structure is analyzed by using finite element method simulation at different intrinsic stress gradients. The gold layers are deposited using cyanide electroplating bath operated at different current densities. Residual stresses in electroplated gold layers deposited on photoresist coated silicon samples are estimated by using X-ray diffraction technique. Cantilever beam structures are fabricated using surface micromachining technique. The tip deflections of the fabricated cantilever beams are found to be ~16 and 8 μm corresponding to the 1.0 and 0.7 mA/cm² current densities (mean), respectively. The corresponding intrinsic stress gradients are estimated to be ?13.9 and ?7.2 MPa/μm, respectively. Simulated and measured values of residual stresses are well matched.     

Residual stress. Part 1 – Measurement techniques

Abstract

Residual stress is that which remains in a body that is stationary and at equilibrium with its surroundings. It can be very detrimental to the performance of a material or the life of a component. Alternatively, beneficial residual stresses can be introduced deliberately. Residual stresses are more difficult to predict than the in-service stresses on which they superimpose. For this reason, it is important to have reliable methods for the measurement of these stresses and to understand the level of information they can provide. In this paper, which is the first part of a two part overview, the effect of residual stresses on fatigue lifetimes and structural integrity are first summarised, followed by the definition and measurement of residual stresses. Different types of stress are characterised according to the characteristic length scale over which they self-equilibrate. By comparing this length to the gauge volume of each technique, the capability of a range of techniques is assessed. In the second part of the overview, the different nature and origins of residual stress for various classes of material are examined.     

A modified layer-removal method for residual stress measurement in electrodeposited nickel films

Combining the traditional layer-removal method with a cantilever beam model, a modified layer-removal method is developed and used to measure residual stress in single and multi-layer electrodeposited nickel films with thickness of 2.5 μm. The out-of-plane displacement of the free tip of a cantilever beam is measured by the digital speckle correlation method. The results show that residual stress in a single semimat nickel film is compressive, while in a multi-layer system composed of dark, semimat and holophote nickel, residual stress in the surface layer is tensile. Residual stress decreases gradually with the increase of etching depths of single and multi-layer films. These findings are in qualitative agreement with nanoindentation tests, which confirms the reliability of the modified layer-removal method.     

Residual stress. Part 2 – Nature and origins

Abstract

Residual stress is that which remains in a body that is stationary and at equilibrium with its surroundings. It can be detrimental when it reduces the tolerance of the material to an externally applied force, as is the case with welded joints. On the other hand, it can be exploited to design materials or components which are resistant to damage, toughened glass being a good example. This paper, the second part of a two part overview, the first part having been devoted to measurement techniques, examines the nature and origins of residual stresses across a range of scales. This extends from the long range residual stress fields in engineering components and welded structures, through the interphase stresses present in composites and coatings, to the microscale interactions of phase transformations with local stresses.     

Characterisation of residual stresses in heat treated,high strength aluminium alloy extrusions

Residual stresses were measured in rectilinear aluminium bars quenched using an aqueous polyoxyethylene glycol (PAG) solution or cold-water. Residual stresses were measured with neutron diffraction and a superposition-based method using mechanical strain release measurements. Three orthogonal stress components were measured along two transverse lines using neutron diffraction. The longitudinal residual stresses were mapped over a transverse cross-section using the contour technique. A primary slice removal technique mapped three orthogonal residual stresses over a transverse cross-section in the PAG extrusion. Residual stresses were found to vary from biaxial compressive in the part boundaries to triaxial tensile in the interiors. There was close correlation between the neutron diffraction and mechanical strain release techniques. PAG quenching demonstrated lower residual stresses.

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

Effect of process parameters on residual stress in selective laser melting of AlSi10Mg

ABSTRACT

Residual stress is a key indicator for measuring complex additive components, and its control method has received extensive attention. In this study, the finite element simulation of selective laser melting of AlSi10Mg was performed. It is found that the opposite laser scanning strategy can reduce the final residual stress of the sample. The effect of preheating the substrate to control the residual stress within a certain temperature range is obvious, and the laser scanning speed has the greatest influence on the Z-direction residual stress of the sample. The results show that the sag phenomenon is easy to occur at the laser scanning starting position, and the formed layer is the maximum residual stress region at the junction with the substrate.     

Eigenspannungen als Messgröße zur Qualitätssicherung

Residual stress as measured quantity in quality assurance The x‐ray method is used in the Volkswagen Automotive Group at different world‐wide locations as a standard procedure to determine residual stress. As an important measured quantity in the quality assurance residual stresses are specified in drawings of different components (e.g. gears, coil springs). Measurements are carried out during quality assurance, production, damage analyse, technical development department and design control of components from suppliers. An optimum efficiency can be achieved, if it exists a unique correlation between residual stress values and loading capacity of components, and if the processes to introduce residual stress can be optimized using residual stress measurements during the production.     

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.     

Manufacturing Residual Stress States in Heat Treatment Simulation of Bearing Rings

Residual stresses generated in the different steps of a manufacturing chain are attached great importance to the distortion due to heat treatment. Because the measurement of residual stress states is associated with large experimental work, the use of simulation would be qualified for the examination of the influence of manufacturing residual stresses on distortion. Due to this reason, a simple method for generating realistic residual stress states by the use of artificial thermal strain in a pre‐simulation step is presented. By changing the thermal strain distributions a wide range of residual stress distributions in a component can be generated. A typical residual stress distribution after machining was generated in a bearing ring. The calculated residual stress profile was in good agreement compared to XRD‐measurement. In a second simulation step the local development of stress relieving during heating was observed. Stress relieving can be attributed to local plastic deformation and rearrangement of stresses.     

Residual stress development and relief in high strength aluminium alloys using standard and retrogression thermal treatments

Abstract

Residual stresses develop in the aluminium alloy 7010 when the material is quenched from the solution heat treatment temperature. Residual stress measurements have been made using the X-ray diffraction technique and a longitudinal split sawcut method to determine the magnitude of residual stress that develops in specimens sectioned from large open die forgings as a result of (a) quenching these specimens into water at different temperatures, and (b) cold water quenching from different furnace temperatures. Residual stress reductions as a result of retrogression and reaging and standard thermal treatments have been determined. The longitudinal split sawcut technique is used to demonstrate the viability of a cheap, rapid technique for determining surface stress magnitudes in specimens of suitable geometry. The variation in room temperature tensile properties of 7010 with natural aging time has also been determined. The surface residual stress magnitudes can significantly exceed the as quenched materials uniaxial limit of proportionality.     

Simplified FE welding simulation of fillet welds – 3D effects on the formation residual stresses

In this study two- and three-dimensional finite element welding simulations have been carried out. The welded component studied is a T-type fillet weld which is frequently used in the heavy vehicle machine industry with plate thicknesses of eight and 20 mm, respectively. The software’s used for the welding simulations is MSC.Marc and ANSYS. The objective is to study the formation of the residual stresses due to 3D effect of the welding process. Moreover, welding simulations using solid models and contact models in the un-fused weld roots were carried out in order to investigate the possible effect with respect to the residual stresses. Residual stress measurements were carried out using X-ray diffraction technique on the manufactured T-welded structure. The 2D residual stress predictions shows good agreement with measurements, hence the 2D welding simulation procedure is suitable for residual stress predictions for incorporation in further fatigue crack growth analysis from weld defects emanating from the weld toe and the un-fused root.     

Calibration of residual stress measurements obtained from EDM hole drilling method using physical material properties

Abstract

When using the electrodischarge machining (EDM) hole drilling method to measure residual stress, the stress induced by the metallurgical transformation layer formed during the drilling process can lead to significant measurement errors. In this study, it is shown that provided the dielectric fluid retains a high level of purity, the stress induced during the drilling process is determined primarily by the thermal conductivity and carbon equivalent of the specimen. Accordingly, these two material properties are used as the basis of two calibration equations designed to compensate the residual stress measurement obtained using the EDM hole drilling method. It is shown that the calibration equations reduce the discrepancy between the actual simulated residual stress values produced by the prestress loadings and the measured residual stress values to less than 8 MPa. The calibration equations provide a significant improvement in the accuracy of the measurement results obtained using the EDM hole drilling technique.     

铸件残余应力的测定和消除方法

介绍了铸件残余应力的产生原因、测定方法扣消除与预测的方法，重点阐述了几种残余应力的测定方法和数值模拟分析在残余应力预测中的应用。数值模拟分析现已成为一种普遍应用的残余应力预测方法。     

Residual stress, Young''s modulus and fracture stress of hot flame deposited diamond

Chemical vapour deposition (CVD) diamond coatings deposited on various substrates usually contain residual stresses. Since the residual stress affects the adhesion of the coating to the substrate, as well as the performance of the coating/substrate composite in many technical applications it is of importance to study the magnitude of these stresses.

In the present study the hot flame method was used to deposit diamond coatings on cemented carbide inserts by scanning the surface with a nine flame nozzle. By varying the oxygen to acetylene flow ratio and the deposition time coatings of different qualities and thicknesses were obtained. The residual strain/stress of the coatings was measured by three different methods: X-ray diffraction using the sin² (Ψ) method, Raman spectroscopy and disc deflection measurements. To extract the residual stress from the strain data the Young's modulus was obtained from bending tests of diamond cantilever beams manufactured from free standing diamond films. The latter technique was also used to determine the fracture stress of the diamond films.

All deposited coatings displayed a residual compressive strain/stress state. The residual strain in the diamond coatings did not vary with coating thickness (1.5 μm to 20 μm) but was found to increase from −1.8 × 10⁻³ to −2.2 × 10⁻³ with decreasing diamond quality. The compressive residual stress was found to decrease from −2 GPa to −1.3 GPa with decreasing diamond quality. This is mainly due to a decrease in Young's modulus (from 1.1 TPa to 0.6 TPa) with decreasing diamond quality. Also the fracture stress was found to decrease (from 1.8 GPa to 0.8 GPa) with decreasing diamond quality. The three methods used for measuring the stress state in the coatings, X-ray diffraction, Raman spectroscopy and deflection measurement, all give the same result. The deflection technique has the advantage that no information about the elastic properties of the coating is needed, whereas Raman spectroscopy has the best lateral resolution (≈5 μm) and is the fastest method (≈5 min).     

An assessment of residual stress mitigation strategies for laser clad deposits

Laser cladding can be used for reclamation or for improving the corrosion resistance of engineering components. However, the process introduces substantial levels of residual stress, which can exacerbate corrosion. In this study, the effectiveness of different residual stress mitigation strategies was investigated. Laser clad overlays were produced by melting an austenitic stainless steel powder onto either an austenitic stainless steel or a mild steel substrate. Residual stresses were measured, using the hole-drilling technique, in the as-clad condition as well as after either laser shock peening (LSP) or post-weld heat treatment (PWHT). Samples were then subjected to corrosion testing. In all cases, LSP delayed the onset of corrosion cracks. However, PWHT was only effective when the substrate and overlay materials matched.

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

Die thermische Stabilität von Eigenspannungen in kugelgestrahlten Oberflächen

Thermal Stability of Residual Stresses in Shot Peened Surfaces . In industry shop peening represents a well-known process to improve the fatigue properties of metallic components. However, the beneficial effect of the induced compressive residual stresses can be reduced if a component is subjected to higher temperatures during service. In this work the relief of the residual stresses as a function of time and temperature is calculated for a 12 %-chromium steel. Specifically, the results can be used for the prediction of the stress relief behaviour of gas turbine compressor blades. This model can also be applied to the determination of the mechanisms which are responsible for the residual stress relief. At temperatures above approximately 300 °C in this material the dominating mechanism is diffusion controlled creep whereas at lower temperatures the stress relief is caused by logarithmic creep.     

Measurement and modelling of residual stress in wire-feed additively manufactured titanium

Residual stresses were characterised in a wire-feed additively manufactured titanium alloy component. A numerical simulation based on the inherent strain method was used to model residual stresses arising from the manufacturing process. The contour method was used to experimentally determine the residual stress field. High tensile residual stresses were seen at and around the interface of the substrate and the deposited metal. Compressive residual stresses were present in the substrate and at the top of the deposit. The satisfactory correlation was achieved between the results from the numerical simulation and the contour method, except for the location of the root of the deposit. The effect of pre-heating the sample substrate on the residual stress distribution is also discussed.     

考虑多组件疲劳损伤的组合梁剩余承载力计算方法及试验验证

针对现行规范中无法计算钢-混凝土组合梁在疲劳后的剩余承载力问题，提出考虑多组件疲劳损伤的组合梁剩余承载力的计算方法。基于材料剩余强度理论，分别引入组合梁各组件（混凝土板、钢梁和栓钉连接件）在疲劳荷载作用下的强度衰减模型；对疲劳荷载作用下的组合梁进行受力分析，得到在既定疲劳荷载幅值下各组件的疲劳应力幅；将各组件的疲劳损伤计入钢-混凝土组合梁剩余抗弯承载力计算中，并考虑疲劳加载过程中组合梁抗剪连接度的变化，建立完全抗剪连接和部分抗剪连接两种情形下的组合梁剩余承载力计算方法，并通过6个试验梁的剩余承载力试验进行验证。研究结果表明:在疲劳荷载作用下，组合梁的抗剪连接度逐渐降低，剩余承载力退化明显且不可忽略。该文建立的组合梁剩余承载力计算方法的计算值与试验值吻合较好，具有良好的计算精度与适用性，补充并完善了现有组合梁承载力的计算方法。     

Analysis of manufacturing effects on fatigue failure of an automotive component using finite element methods

In this study, the fatigue life of an automotive suspension component was analysed using finite element methods with regard to stamping and welding effects. Because automotive suspension components are produced by forming and welding sheet metal, there are various effects on the final product, such as uneven thickness distribution, residual stresses and weld notches. Manufacturing effects may change the mechanical performance of the automotive components; therefore, it is desirable to consider these effects in the early design stage. Residual stresses due to work hardening and thermal deformation were investigated through process simulation. The redistribution and relaxation of residual stresses in a component were investigated in fatigue life analysis under a cyclic loading condition. Various equivalent relaxation curves were investigated and one was selected after comparisons with test results. The fatigue simulation results were compared to the test results; a good correlation between the two was achieved for the residual stress effects in terms of life cycles and failure locations. The simulation results also show that welding produces more detrimental effects than stamping with regard to the fatigue life of a component.     

纳米黏弹性测量中谐振抑制方法研究

针对压痕测量软材料中悬臂梁谐振导致测量数据存在较大误差的问题,提出一种在宽带纳米黏弹性测量中抑制悬臂梁谐振的方法。基于z轴动态特性设计一种陷波器类型的前置滤波器,并对输入驱动电压进行滤波;设计基于最小均方误差准则(LMS)的自适应滤波器,参考赫兹接触模型对软材料的复蠕变量进行滤波,进而在输入环节和测量环节消除谐振影响。通过二甲基硅氧烷(PDMS)样本的黏弹性测量实验,验证悬臂梁谐振抑制方法的有效性。