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DOE OSTI2021

Plasticity and fracture behavior of Inconel 625 manufactured by laser powder bed fusion: Comparison between as-built and stress relieved conditions

In this work, the influence of stress relief on the plasticity and fracture behavior of Inconel 625 fabricated through laser powder bed fusion additive manufacturing (AM) was investigated. The as-built versus stress relieved microstructures were compared, showing similar grain structures but the presence of ~10 vol % δ phase in the stress relieved condition, and no δ phase in the as-built condition. Mechanical tests under plane strain tension were performed on the stress relieved samples, and an anisotropic plasticity model was calibrated and validated using finite element simulations. Uniaxial and notched tension tests were performed on both as-built and stress relieved samples to probe the effect of stress relief on stress state- and direction-dependent fracture behavior. It was found that on average, the fracture strain of the stress relieved samples along the build direction was 30% higher than that along the perpendicular build direction in the stress state range studied, and the stress relief heat treatment resulted in a 45% decrease in fracture strain. The fracture strain in stress relieved samples was more strongly dependent on stress state than in as-built samples.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Genome-wide profiling of histone (H3) lysine 4 (K4) tri-methylation (me3) under drought, heat, and combined stresses in switchgrass

Background: Switchgrass (Panicum virgatum L.) is a warm-season perennial (C4) grass identified as an important biofuel crop in the United States. It is well adapted to the marginal environment where heat and moisture stresses predominantly affect crop growth. However, the underlying molecular mechanisms associated with heat and drought stress tolerance still need to be fully understood in switchgrass. The methylation of H3K4 is often associated with transcriptional activation of genes, including stress-responsive. Therefore, this study aimed to analyze genome-wide histone H3K4-tri-methylation in switchgrass under heat, drought, and combined stress. Results: In total, ~ 1.3 million H3K4me3 peaks were identified in this study using SICER. Among them, 7,342; 6,510; and 8,536 peaks responded under drought (DT), drought and heat (DTHT), and heat (HT) stresses, respectively. Most DT and DTHT peaks spanned 0 to + 2000 bases from the transcription start site [TSS]. By comparing differentially marked peaks with RNA-Seq data, we identified peaks associated with genes: 155 DT-responsive peaks with 118 DT-responsive genes, 121 DTHT-responsive peaks with 110 DTHT-responsive genes, and 175 HT-responsive peaks with 136 HT-responsive genes. We have identified various transcription factors involved in DT, DTHT, and HT stresses. Gene Ontology analysis using the AgriGO revealed that most genes belonged to biological processes. Most annotated peaks belonged to metabolite interconversion, RNA metabolism, transporter, protein modifying, defense/immunity, membrane traffic protein, transmembrane signal receptor, and transcriptional regulator protein families. Further, we identified significant peaks associated with TFs, hormones, signaling, fatty acid and carbohydrate metabolism, and secondary metabolites. qRT-PCR analysis revealed the relative expressions of six abiotic stress-responsive genes (transketolase, chromatin remodeling factor-CDH3, fatty-acid desaturase A, transmembrane protein 14C, beta-amylase 1, and integrase-type DNA binding protein genes) that were significantly (P < 0.05) marked during drought, heat, and combined stresses by comparing stress-induced against un-stressed and input controls. Conclusion: Our study provides a comprehensive and reproducible epigenomic analysis of drought, heat, and combined stress responses in switchgrass. Significant enrichment of H3K4me3 peaks downstream of the TSS of protein-coding genes was observed. In addition, the cost-effective experimental design, modified ChIP-Seq approach, and analyses presented here can serve as a prototype for other non-model plant species for conducting stress studies.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2015

Techniques for Achieving Zero Stress in Thin Films of Iridium, Chromium, and Nickel

We examine techniques for achieving zero intrinsic stress in thin films of iridium, chromium, and nickel deposited by magnetron sputter deposition. The intrinsic stress is further correlated to the microstructural features and physical properties such as surface roughness and optical density at a scale appropriate to soft X-ray wavelengths. The examination of the stress in these materials is motivated by efforts to advance the optical performance of light-weight X-ray space telescopes into the regime of sub-arcsecond resolution through various deposition techniques that rely on control of the film stress to values within 10-100 MPa. A characteristic feature of the intrinsic stress behavior in chromium and nickel is their sensitivity to the magnitude and sign of the intrinsic stress with argon gas pressure and deposition rate, including the existence of a critical argon process pressure that results in zero film stress which scales linearly with the atomic mass of the sputtered species. While the effect of stress reversal with argon pressure has been previously reported by Hoffman and others for nickel and chromium, we report this effect for iridium. In addition to stress reversal, we identify zero stress in the optical functioning iridium layer shortly after island coalescence for low process pressures at a film thickness of approximately 35nm. The measurement of the low values of stress during deposition was achieved with the aid of a sensitive in-situ instrument capable of a minimum detectable level of stress, assuming a 35nm thick film, in the range of 0.40-6.0 MPa for <111> oriented crystalline silicon substrate thicknesses of 70-280 microns, respectively.

X-ray optical thin films↗

DOE OSTI2026

Mapping the Residual Stress Distribution in Polycrystalline Quartz Tiger's Eye Using Raman Spectroscopy

Stress distribution maps in polycrystalline materials are needed to reveal stress pathways caused by short‐and long‐range interactions of crystallites. Stress induced changes to wavenumbers in Raman spectroscopy is a well‐known phenomenon that occurs when a crystalline material undergoes elastic strain. Using spatially resolved Raman spectroscopy, we have developed a technique to experimentally measure grain‐scale residual stresses across a sample of polycrystal quartz Tiger's Eye. The results of this technique are validated using multiple criteria, including evaluation of the residual stress map itself and the accuracy of the measurements taken. The residual map of Tiger's Eye shows striking similarity to observed characteristics of other polycrystalline residual stress distributions, revealing heterogenous areas of high and low magnitude stresses. The stress magnitudes are consistent with residual stress magnitudes previously measured from polycrystalline quartz. Characterization of Tiger's Eye quartz also revealed the geometric nature of the iron oxide inclusions, not previously observed in Tiger's Eye quartz. With this technique, we present a residual stress map of Tiger's Eye quartz that shows with accuracy a heterogeneous stress state with inter‐ and intra‐granular detail.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Using in-situ strain measurements to evaluate the accuracy of stress estimation procedures from fracture injection/shut-in tests

Fracture injection/shut-in tests are commonly used to measure the state of stress. Injection creates a hydraulic fracture (or in some cases, opens a preexisting fracture), and then the pressure after shut-in is monitored to identify fracture closure. Different interpretation procedures have been proposed for estimating closure, and the procedures sometimes yield significantly different results. In this study, direct, in-situ strain measurements are used to observe fracture reopening and closure. The tests were performed as part of the EGS Collab project, a mesoscale project performed at 1.25 and 1.5 km depth at the Sanford Underground Research Facility. The tests were instrumented with the SIMFIP tool, a double-packer probe with a high-resolution three-dimensional borehole displacement sensor. The measurements provide a direct observation of the fracture closure signature, enabling a high-fidelity estimate of the fracture closure stress (ie, the normal stress on the fracture). In two of the four tests, injection created an opening mode fracture, and so the closure stress can be interpreted as the minimum principal stress. In the other two tests, injection probably opened preexisting natural fractures, and so the closure stress can be interpreted as the normal stress on the fractures. The strain measurements are compared against different proposed methods for estimating closure stress from pressure transients. The shut-in transients are analyzed with two techniques that are widely used in the field of petroleum engineering – the ‘tangent’ method and the ‘compliance’ method. In three of the four tests, the tangent method significantly underestimates the closure stress. The compliance method is reasonably accurate in all four tests. Closure stress is also interpreted using two other commonly-used methods – ‘first deviation from linearity’ and the method of Hayashi and Haimson. In comparison with the SIMFIP data, these methods tend to overestimate the closure stress, evidently because they identify closure from early-time transient effects, such as near-wellbore tortuosity. In two of the tests, microseismic imaging provides an independent estimate of the size of the fracture created by injection. When combined with a simple mass balance calculation, the SIMFIP stress measurements yield predictions of fracture size that are reasonably consistent with the estimates from microseismic. In conclusion, the calculations imply an apparent fracture toughness 2-3x higher than typical laboratory-derived values.

58 GEOSCIENCES↗

NASA NTRS1978

Role of back stress in the creep behavior of particle strengthened alloys

Recent developments in the interpolation of high-temperature steady-state creep results have introduced the concept that the stress dependence of the creep rate should be in terms of the effective stress referred to as the applied stress minus a back stress. This paper reports on back stresses taken from data on a gamma-prime-strengthened wrought nickel-base superalloy, an oxide dispersion-strengthened ODS nickel-base solid solution alloy, and an ODS nickel-base superalloy. The effect of air versus vacuum environments and the effect of dynamic changes in the strengthening microstructures on the magnitude of the back stress are assessed. The role of modulus normalization and the back stress correction in determining the true creep activation energy are examined. It is shown that the high values of the apparent stress exponent 'n' of the steady-state creep equation can be easily explained through a relationship between n, the true stress exponent of steady-state creep, and the stress which when subtracted from the applied stress results in the effective driving stress acting on the mobile dislocations during creep.

Purushothaman, S.↗

NASA NTRS1993

Thermal stress effects in intermetallic matrix composites

Intermetallic matrix composites develop residual stresses from the large thermal expansion mismatch (delta-alpha) between the fibers and matrix. This work was undertaken to: establish improved techniques to measure these thermal stresses in IMC's; determine residual stresses in a variety of IMC systems by experiments and modeling; and, determine the effect of residual stresses on selected mechanical properties of an IMC. X ray diffraction (XRD), neutron diffraction (ND), synchrotron XRD (SXRD), and ultrasonics (US) techniques for measuring thermal stresses in IMC were examined and ND was selected as the most promising technique. ND was demonstrated on a variety of IMC systems encompassing Ti- and Ni-base matrices, SiC, W, and Al2O3 fibers, and different fiber fractions (Vf). Experimental results on these systems agreed with predictions of a concentric cylinder model. In SiC/Ti-base systems, little yielding was found and stresses were controlled primarily by delta-alpha and Vf. In Ni-base matrix systems, yield strength of the matrix and Vf controlled stress levels. The longitudinal residual stresses in SCS-6/Ti-24Al-llNb composite were modified by thermomechanical processing. Increasing residual stress decreased ultimate tensile strength in agreement with model predictions. Fiber pushout strength showed an unexpected inverse correlation with residual stress. In-plane shear yield strength showed no dependence on residual stress. Higher levels of residual tension led to higher fatigue crack growth rates, as suggested by matrix mean stress effects.

Wright, P. K.↗

NASA NTRS2000

Transverse Stress Decay in a Specially Orthotropic Strip Under Localizing Normal Edge Loading

Solutions are presented for the stresses in a specially orthotropic infinite strip which is subjected to localized uniform normal loading on one edge while the other edge is either restrained against normal displacement only, or completely fixed. The solutions are used to investigate the diffusion of load into the strip and in particular the decay of normal stress across the width of the strip. For orthotropic strips representative of a broad range of balanced and symmetric angle-ply composite laminates, minimum strip widths are found that ensure at least 90% decay of the normal stress across the strip. In addition, in a few cases where, on the fixed edge the peak shear stress exceeds the normal stress in magnitude, minimum strip widths that ensure 90% decay of both stresses are found. To help in putting these results into perspective, and to illustrate the influence of material properties on load 9 orthotropic materials, closed-form solutions for the stresses in similarly loaded orthotropic half-planes are obtained. These solutions are used to generate illustrative stress contour plots for several representative laminates. Among the laminates, those composed of intermediate-angle plies, i.e., from about 30 degrees to 60 degrees, exhibit marked changes in normal stress contour shape with stress level. The stress contours are also used to find 90% decay distances in the half-planes. In all cases, the minimum strip widths for 90% decay of the normal stress exceed the 90% decay distances in the corresponding half-planes, in amounts ranging from only a few percent to about 50% of the half-plane decay distances. The 90% decay distances depend on both material properties and the boundary conditions on the supported edge.

Fichter, W. B.↗

NASA NTRS2008

Using Hyperspectral Imagery to Identify Turfgrass Stresses

The use of a form of remote sensing to aid in the management of large turfgrass fields (e.g. golf courses) has been proposed. A turfgrass field of interest would be surveyed in sunlight by use of an airborne hyperspectral imaging system, then the raw observational data would be preprocessed into hyperspectral reflectance image data. These data would be further processed to identify turfgrass stresses, to determine the spatial distributions of those stresses, and to generate maps showing the spatial distributions. Until now, chemicals and water have often been applied, variously, (1) indiscriminately to an entire turfgrass field without regard to localization of specific stresses or (2) to visible and possibly localized signs of stress for example, browning, damage from traffic, or conspicuous growth of weeds. Indiscriminate application is uneconomical and environmentally unsound; the amounts of water and chemicals consumed could be insufficient in some areas and excessive in most areas, and excess chemicals can leak into the environment. In cases in which developing stresses do not show visible signs at first, it could be more economical and effective to take corrective action before visible signs appear. By enabling early identification of specific stresses and their locations, the proposed method would provide guidance for planning more effective, more economical, and more environmentally sound turfgrass-management practices, including application of chemicals and water, aeration, and mowing. The underlying concept of using hyperspectral imagery to generate stress maps as guides to efficient management of vegetation in large fields is not new; it has been applied in the growth of crops to be harvested. What is new here is the effort to develop an algorithm that processes hyperspectral reflectance data into spectral indices specific to stresses in turfgrass. The development effort has included a study in which small turfgrass plots that were, variously, healthy or subjected to a variety of controlled stresses were observed by use of a hand-held spectroradiometer. The spectroradiometer readings in the wavelength range from 350 to 1,000 nm were processed to extract hyperspectral reflectance data, which, in turn, were analyzed to find correlations with the controlled stresses. Several indices were found to be correlated with drought stress and to be potentially useful for identifying drought stress before visible symptoms appear.

Hutto, Kendall↗

NASA NTRS2010

Modeling the Effects of Stress: An Approach to Training

Stress is an integral element of the operational conditions experienced by combat medics. The effects of stress can compromise the performance of combat medics who must reach and treat their comrades under often threatening circumstances. Examples of these effects include tunnel vision, loss of motor control, and diminished hearing, which can result in an inability to perceive further danger, satisfactorily treat the casualty, and communicate with others. While many training programs strive to recreate this stress to aid in the experiential learning process, stress inducement may not always be feasible or desired. In addition, live simulations are not always a practical, convenient, and repeatable method of training. Instead, presenting situational training on a personal computer is proposed as an effective training platform in which the effects of stress can be addressed in a different way. We explore the cognitive and motor effects of stress, as well as the benefits of training for mitigating these effects in real life. While many training applications focus on inducing stress in order to "condition" the stress response, the author explores the possibilities of modeling stress to produce a similar effect. Can presenting modeled effects of stress help prepare or inoculate soldiers for stressful situations in which they must perform at a high level? This paper investigates feasibility of modeling stress and describes the preliminary design considerations of a combat medic training system that utilizes this method of battlefield preparation.

Cuper, Taryn↗

NASA NTRS2015

Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

Newman, John A.↗

NASA NTRS2017

Shallow Lunar Seismic Activity and the Current Stress State of the Moon

A vast, global network of more than 3200 lobate thrust fault scarps has been revealed in high resolution Lunar Reconnaissance Orbiter Camera (LROC) images. The fault scarps are very young, less than 50 Ma, based on their small scale and crisp appearance, crosscutting relations with small-diameter impact craters, and rates of infilling of associated small, shallow graben and may be actively forming today. The population of young thrust fault scarps provides a window into the recent stress state of the Moon and offers insight into the origin of global lunar stresses. The distribution of orientations of the fault scarps is non-random, inconsistent with isotropic stresses from late-stage global contraction as the sole source of stress. Modeling shows that tidal stresses contribute significantly to the current stress state of the lunar crust. Tidal stresses (orbital recession and diurnal tides) superimposed on stresses from global contraction result in non-isotropic compressional stress and may produce thrust faults consistent with lobate scarp orientations. At any particular point on the lunar surface, peak compressive stress will be reached at a certain time in the diurnal cycle. Coseismic slip events on currently active thrust faults are expected to be triggered when peak stresses are reached. Analysis of the timing of the 28 the shallow moonquakes recorded by the Apollo seismic network shows that 19 indeed occur when the Moon is closer to apogee, while only 9 shallow events occur when the Moon is closer to perigee. Here we report efforts to refine the model for the current stress state of the Moon by investigating the contribution of polar wander. Progress on relocating the epicentral locations of the shallow moonquakes using an algorithm designed for sparse networks is also reported.

structure↗

DOE OSTI2021

Identification of Metal Stresses in Arabidopsis thaliana Using Hyperspectral Reflectance Imaging

Industrial accidents, such as the Fukushima and Chernobyl disasters, release harmful chemicals into the environment, covering large geographical areas. Natural flora may serve as biological sensors for detecting metal contamination, such as cesium. Spectral detection of plant stresses typically employs a few select wavelengths and often cannot distinguish between different stress phenotypes. In this study, we apply hyperspectral reflectance imaging in the visible and near-infrared along with multivariate curve resolution (MCR) analysis to identify unique spectral signatures of three stresses in Arabidopsis thaliana : salt, copper, and cesium. While all stress conditions result in common stress physiology, hyperspectral reflectance imaging and MCR analysis produced unique spectral signatures that enabled classification of each stress. As the level of potassium was previously shown to affect cesium stress in plants, the response of A. thaliana to cesium stress under variable levels of potassium was also investigated. Increased levels of potassium reduced the spectral response of A. thaliana to cesium and prevented changes to chloroplast cellular organization. While metal stress mechanisms may vary under different environmental conditions, this study demonstrates that hyperspectral reflectance imaging with MCR analysis can distinguish metal stress phenotypes, providing the potential to detect metal contamination across large geographical areas.

multivariate curve resolution↗

DOE OSTI2022

Stress evolution and thickness change of a lithium-ion pouch cell under various cycling conditions

We report to design large-sized lithium-ion battery modules for the application of electric vehicles and grid-level energy storage, it is of important significance to understand how stress and dimension of a single pouch cell fluctuate during charge/discharge cycles. In this study, stress evolution under the constant-thickness condition and thickness change under the constant-stress condition are measured for in-house fabricated pouch cells, respectively. The results of stress measurements show that the stress increase percentage generally decreases when the charge/discharge current increases, regardless of the value of the initial compressive stress. With the same current density, the stress increase percentage generally increases when the upper cutoff voltage increases. With the same current density and upper cutoff voltage, the stress increase percentage decreases when the initial compressive stress increases. The results of thickness measurements show that the volume expansion percentage generally increases when the current density increases, regardless of the value of the constant compressive stress. With the same current density, the volume expansion percentage generally increases when the upper cutoff voltage increases. With the same current density and upper cutoff voltage, the volume expansion decreases when the constant compressive stress increases. The results provide important insights into the design principles of battery packs.

25 ENERGY STORAGE↗

DOE OSTI2021

A 3D Full Stress Tensor Model for Oklahoma

Abstract The stress tensor is an important property for upper crustal studies such as those that involve pore fluids and earthquake hazards. At tectonic plate scale, plate boundary forces and mantle convection are the primary drivers of the stress field. In many local settings (10–100 s of km and <10 km depth) in tectonic plate interiors, we can simplify by assuming a constant background stress field that is perturbed by local heterogeneity in density and elasticity. Local stress orientation and sometimes magnitude can be estimated from earthquake and borehole‐based observations when available. Modeling of the local stress field often involves interpolating sparse observations. We present a new method to estimate the 3D stress field in the upper crust and demonstrate it for Oklahoma. We created a 3D material model by inverting multiple types of geophysical observations simultaneously. Integrating surface‐wave dispersion, local travel times and gravity observations produces a model of P‐wave velocity, S‐wave velocity, and density. The stress field can then be modeled using finite element simulations. The simulations are performed using our simplified view of the local stress field as the sum of a constant background stress field that is perturbed by local density and elasticity heterogeneity and gravitational body forces. An orientation of N82°E, for the maximum compressive tectonic force, best agrees with previously observed stress orientations and faulting types in Oklahoma. The gravitational contribution of the horizontal stress field has a magnitude comparable to the tectonic contribution for the upper 5 km of the subsurface.

58 GEOSCIENCES↗

DOE OSTI2020

Development of a Stress Sensor for In-Situ High-Pressure Deformation Experiments Using Radial X-Ray Diffraction

We developed a stress sensor for in-situ deformation experiments using synchrotron radial X-ray diffraction. This stress sensor provided nearly diffraction-plane-independent stress that, when used in series with a sample, reduced the uncertainty of the average stress estimation acting on a sample. Here, we present the results of a study where pyrope was used as a stress sensor. Using a Deformation-DIA (D-DIA) high-pressure deformation apparatus, pyrope, olivine and alumina were deformed in the same run/cell assembly placed in series along the compression direction. Deformation experiments were conducted at pressures between 4 and 5 GPa and temperatures between 730 and 1273 K with strain-rates between 10 –5 and 10 –6 s –1 . Stresses estimated from various (hkl) planes in pyrope were nearly the same; i.e., pyrope is plastically isotropic with ≤10 % variation with (hkl). However, stresses from various (hkl) planes in olivine and alumina varied by approximately a factor of 3. Comparisons between average stresses inferred from pyrope and those from different diffraction planes in olivine and alumina showed that the average stress in these materials evolved from low-end stress, estimated from various (hkl) planes at small strain, to high-end stress at a large strain. This suggests that the rate-controlling slip system in these materials changes from the soft to the hard slip system with strain.

58 GEOSCIENCES↗

NASA NTRS2016

Separating the Influence of Environment from Stress Relaxation Effects on Dwell Fatigue Crack Growth in a Nickel-Base Disk Alloy

Both environmental embrittlement and crack tip visco-plastic stress relaxation play a significant role in determining the dwell fatigue crack growth (DFCG) resistance of nickel-based disk superalloys. In the current study performed on the Low Solvus High Refractory (LSHR) disk alloy, the influence of these two mechanisms were separated so that the effects of each could be quantified and modeled. Seven different microstructural variations of LSHR were produced by controlling the cooling rate and the subsequent aging and thermal exposure heat treatments. Through cyclic fatigue crack growth testing performed both in air and vacuum, it was established that four out of the seven LSHR heat treatments evaluated, possessed similar intrinsic environmental resistance to cyclic crack growth. For these four heat treatments, it was further shown that the large differences in dwell crack growth behavior which still persisted, were related to their measured stress relaxation behavior. The apparent differences in their dwell crack growth resistance were attributed to the inability of the standard linear elastic fracture mechanics (LEFM) stress intensity parameter to account for visco-plastic behavior. Crack tip stress relaxation controls the magnitude of the remaining local tensile stresses which are directly related to the measured dwell crack growth rates. It was hypothesized that the environmentally weakened grain boundary crack tip regions fail during the dwells when their strength is exceeded by the remaining local crack tip tensile stresses. It was shown that the classical creep crack growth mechanisms such as grain boundary sliding did not contribute to crack growth, but the local visco-plastic behavior still plays a very significant role by determining the crack tip tensile stress field which controls the dwell crack growth behavior. To account for the influence of the visco-plastic behavior on the crack tip stress field, an empirical modification to the LEFM stress intensity parameter, Kmax, was developed by incorporating into the formulation the remaining stress level concept as measured by simple stress relaxation tests. The newly proposed parameter, Ksrf, did an excellent job in correlating the dwell crack growth rates for the four heat treatments which were shown to have similar intrinsic environmental cyclic fatigue crack growth resistance.

Dwell crack growth↗

DOE OSTI2020

Complementary Measurements of Residual Stresses Before and After Base Plate Removal in an Intricate Additively-Manufactured Stainless-Steel Valve Housing

Residual stress measurements using neutron diffraction and the contour method were performed on a valve housing made from 316 L stainless steel powder with intricate three-dimensional internal features using laser powder-bed fusion additive manufacturing. The measurements captured the evolution of the residual stress fields from a state where the valve housing was attached to the base plate to a state where the housing was cut free from the base plate. Making use of this cut, thus making it a non-destructive measurement in this application, the contour method mapped the residual stress component normal to the cut plane (this stress field is completely relieved by cutting) over the whole cut plane, as well as the change in all stresses in the entire housing due to the cut. The non-destructive nature of the neutron diffraction measurements enabled measurements of residual stress at various points in the build prior to cutting and again after cutting. Good agreement was observed between the two measurement techniques, which showed large, tensile build-direction residual stresses in the outer regions of the housing. The contour results showed large changes in multiple stress components upon removal of the build from the base plate in two distinct regions: near the plane where the build was cut free from the base plate and near the internal features that act as stress concentrators. These observations should be useful in understanding the driving mechanisms for builds cracking near the base plate and to identify regions of concern for structural integrity. Neutron diffraction measurements were also used to show the shear stresses near the base plate were significantly lower than normal stresses, an important assumption for the contour method because of the asymmetric cut.

36 MATERIALS SCIENCE↗