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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Residual stresses distribution, correlated with bending tests, within explosively welded Ti gr. 2/A1050 bimetals

Highlights: • Ti gr.2/A1050 clad was slightly affected by the explosive welding since negative sign values of stress tensor were detected. • Upon bending higher negative compression stresses were detected in this area. • Twins morphology changed from parallel to cross-shaped arrangement as a consequence of bending. • The compressive twinning was the dominant system before and after three point bending. - Abstract: Synchrotron radiation and XRD{sup 2} method were used to investigate the residual stress distribution before and after three point bending tests within an explosively welded composite composed of two light metals, namely: Ti gr. 2 and A1050. The analysis has shown that the bimetal is slightly affected by the explosive welding process since negative sign values of stress tensor were detected only in the immediate vicinity of interface of Ti gr. 2 characterized by a width of about 0.25 mm. Upon bending higher negative compression stresses are detected in this area as the σ{sub 11} value changes from −500 MPa to −1200 MPa. Additionally, the analysis of microstructure has revealed significant changes in twins morphology with primary and conjugate twinning before and after bending, respectively. However, the compressive twinning was the dominant system in both cases. Bending has changed the initial bimodal texture developing more spread basal components towards the transverse direction. The sample surface has been also significantly affected as the presence of compressive residual stress (−500 MPa) after bending was measured.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys

In this study, the complex relationship between deformation history and residual stresses in a magnesium-to-aluminum self-pierce riveted (SPR) joint is elucidated using numerical and experimental approaches. Non-linear finite element (FE) simulations incorporating strain rate and temperature effects were performed to model the deformation in the SPR process. In order to accurately capture the deformation, a stress triaxiality-based damage material model was employed to capture the sheet piercing from the rivet. Strong visual comparison between the physical cross-section of the SPR joint and the simulation was achieved. To aid in understanding of the role of deformation in the riveting process and to validate the modeling approach, several experimental measurements were conducted. To quantify the plastic deformation from the piercing of the rivet, micro hardness mapping was performed on a cross-section of the SPR joint. The FE model showed very strong correlation to the experimental hardness mapping results suggesting the nonlinear model captured the plastic deformation with high accuracy. To measure the elastic residual stresses in the SPR joint, neutron and x-ray diffraction mapping techniques were conducted and in general, the FE model correlated well to the trends and magnitudes of the elastic stresses. While some error occurred in between the model and the neutron and x-ray diffraction results, the numerical approach developed in this study shows potential as a tool for understanding SPR behavior as well as optimizing the process parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Residual Stresses in SAVY 4000 and Hagan Container Bodies

Chloride-induced stress corrosion cracking (SCC) has been investigated as a potential failure mechanism for the SAVY 4000 and the Hagan containers used to store plutonium-bearing materials at Los Alamos National Laboratory. This report discusses the regions of the container bodies most susceptible to SCC and the magnitude of the residual stresses in those regions. Boiling MgCl2 testing indicated that for both containers the region near the top weld was most susceptible to SCC. The Hagan showed through wall cracking after 22-24 hours of exposure both parallel (axial stresses) and perpendicular (hoop stresses) to the weld. The SAVY 4000 container showed significant cracking above and below the weld after 47 hours of exposure but there was no visual evidence of a through wall crack and the cracks did not leak water. Two through wall holes formed in the bottom of the SAVY 4000 container after 44-46 hours of exposure. For both containers, average “through wall” residual stresses were determined from hole drilling data 4 mm below the weld. In the Hagan body, average tensile hoop stresses were 194 MPa and average compressive axial stresses were -120 MPa. In the SAVY 4000 body, average compressive hoop stresses were 11 MPa and average tensile axial stresses were 25 MPa. Results suggest that because the Hagan container exhibited through wall cracking in a shorter time in boiling MgCl2 and had the higher average tensile stress, 194 MPa hoop stress, it is more susceptible to SCC than the SAVY 4000 container.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1987

Low-field magnetoacoustic residual stress measurement in steel

Much of the recent development of the magnetoacoustic technique has been devoted to refine this technique as a reliable and practical tool for measuring bulk residual stress in steel components. For this, the effects of structural and metallurgical properties on the magnetoacoustic interaction have been studied for various types of steel samples. Also, progress is being made to obtain quantitative residual stress measurements in railroad wheels. This paper reviews the physical basis and the experimental results of the magnetoacoustic stress measurements in steels.

Namkung, M.↗
DOE OSTI2013

Residual stress relief due to fatigue in tetragonal lead zirconate titanate ceramics

High energy synchrotron XRD was employed to determine the lattice strain {epsilon}{l_brace}111{r_brace}and diffraction peak intensity ratio R{l_brace}200{r_brace}in tetragonal PZT ceramics, both in the virgin poled state and after a bipolar fatigue experiment. It was shown that the occurrence of microstructural damage during fatigue was accompanied by a reduction in the gradient of the {epsilon}{l_brace}111{r_brace}-cos{sup 2} {psi} plot, indicating a reduction in the level of residual stress due to poling. In contrast, the fraction of oriented 90 Degree-Sign ferroelectric domains, quantified in terms of R{l_brace}200{r_brace}, was not affected significantly by fatigue. The change in residual stress due to fatigue is interpreted in terms of a change in the average elastic stiffness of the polycrystalline matrix due to the presence of inter-granular microcracks.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗
NASA NTRS1990

Interferometric Measurement Of Residual Stress

Stress averaged through thickness of plate measured nondestructively. Theory of elasticity combined with laser interferometric technique into technique for measurement of residual stresses in solid objects - usually in thin, nominally-flat plates. Measurements particularly useful in inspection of wafers of single-crystal silicon for making solar cells or integrated circuits, because stresses remaining after crystal-growing process cause buckling or fracture. Used to predict deflections of plates caused by known applied loads under specified boundary condition, or to infer applied loads that cause known deflections. Also used to relate known deflections to residual stresses equivalent to stresses produced by fictitious applied loads.

Danyluk, Steven↗
DOE OSTI2013

Relationship between dislocations and residual stresses in cold-drawn pearlitic steel analyzed by energy-dispersive X-ray diffraction

We analyzed the dislocation distribution of cold-drawn pearlitic-steel wire by using the line-profile analysis based on the energy dispersive X-ray diffraction (EDXD). Although this line-profile analysis requires a high resolution in reciprocal space, the resolution for EDXD is generally poor due to the energy resolution of the detector. Our analysis demonstrated that the resolution in the reciprocal space can be maximized at small scattering angles. Using the line-profile analysis based on the EDXD, the microstructural parameters such as the crystallite size and the dislocation density of the ferrite phase in the pearlitic steel were successfully analyzed. In addition, the distribution of the residual stress of the ferrite phase of a pearlitic steel wire was also analyzed using the EDXD measurement. - Highlights: • Energy dispersive X-ray diffraction is applied to the line-profile analysis. • Distribution of dislocations in ferrite in the pearlitic steel wire is analyzed. • Relationship between dislocations and residual stress is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Local residual stresses and microstructure within recrystallizing grains in iron

The intragranular strains and the microstructure within recrystallizing grains in single phase pure iron have been systematically studied in 3D using synchrotron micro-diffraction. In contradiction to common knowledge we observe that residual elastic strains of up to 1–2 × 10 –3 are present in the recrystallizing grains. The local strain variations within individual grains can be similar in magnitude to those between different grains. The effects of processing parameters, including rolling reduction, recrystallized volume fraction, and cooling rate, as well as microstructural parameters, including grain size, orientation and internal misorientation, on the development of local residual elastic strains and microstructure have been quantified. It is suggested that the difference in local defect density between recrystallized grains and the surrounding deformed matrix, as well as the redistribution of medium to long-range residual stresses in the deformed grains, are the main reasons for the development of such strains in the recrystallized grains. The local residual stress levels are calculated and their possible impact on the mechanical properties and recrystallization processes are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Exploratory Studies of Mechanical Properties, Residual Stress, and Grain Evolution at the Local Regions near Pores in Additively Manufactured Metals

Directed energy deposition (DED) is gaining widespread acceptance in various industrial applications since its unique manufacturing features allow the DED to print metallic parts with very complex geometries. However, DED inevitably generates a lot of internal pores which can limit the widespread applications of the DED technique. The current studies on DED porosity are mostly focused on analyzing pores’ bulk-scale influences on mechanical properties and performances. Since DED pores have a micro-scale existence, with dimensions ranging from a few microns to several hundred microns, it is fundamental to explore the pores’ influences on the micro-scale, including local mechanical properties, residual stress, and grains near pores. However, this important research direction has been neglected. The objective of this work is to fill the above gap in DED porosity research and acquire a fundamental understanding of the role of porosity on a microscopic scale. The authors used nanoindentation approaches to investigate internal pores’ effects on mechanical properties and residual stress in local regions surrounding the pores. In addition, the grains near pores were observed through EBSD, and simulated with the Kinetic Monte Carlo model. The research findings can be provided for DED researchers and industrial practitioners as technical guidance. Most importantly, the research results can work as a good reference for tracing the source of bulk-scale mechanical performances and properties of DED parts with internal pores.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Scanning electron acoustic microscopy of residual stresses in ceramics - Theory and experiment

The paper presents a three-dimensional mathematical model of signal generation and contrast in brittle materials and uses the model to simulate the effect of residual stress fields on the scanning electron acoustic microscopy (SEAM)-generated electron acoustic signal. According to the model, a positive (tensile) strain produces an increase in the output signal, whereas a negative (compressive) strain produces a decrease in the ouput signal. Dark field contrast conditions occur at a chopping frequency at which V2 - V1 is greater than 0 (where V2 = V is the SEAM output in a region of residual stresses, and V1 is the output in a stress-free region of the sample). Under ideal conditions (maximum contrast) V1 approaches zero. It was found that tensile strains of the order 0.2-0.3 percent, possible in brittle materials, would produce a variation of the acoustic output signal of the order 10 nV (about 1 percent), well within the image contrast and signal processing capability of the SEAM electronics.

Cantrell, John H.↗
NASA NTRS1998

Mechanical Characterization of Thermomechanical Matrix Residual Stresses Incurred During MMC Processing

In recent years, much effort has been spent examining the residual stress-strain states of advanced composites. Such examinations are motivated by a number of significant concerns that affect composite development, processing, and analysis. The room-temperature residual stress states incurred in many advanced composite systems are often quite large and can introduce damage even prior to the first external mechanical loading of the material. These stresses, which are induced during the cooldown following high-temperature consolidation, result from the coefficient of thermal expansion mismatch between the fiber and matrix. Experimental techniques commonly used to evaluate composite internal residual stress states are non-mechanical in nature and generally include forms of x-ray and neutron diffraction. Such approaches are usually complex, involving a number of assumptions and limitations associated with a wide range of issues, including the depth of penetration, the volume of material being assessed, and erroneous effects associated with oriented grains. Furthermore, and more important to the present research, these techniques can assess only "single time" stress in the composite. That is, little, if any, information is obtained that addresses the time-dependent point at which internal stresses begin to accumulate, the manner in which the accumulation occurs, and the presiding relationships between thermoelastic, thermoplastic, and thermoviscous behaviors. To address these critical issues, researchers at the NASA Lewis Research Center developed and implemented an innovative mechanical test technique to examine in real time, the time-dependent thermomechanical stress behavior of a matrix alloy as it went through a consolidation cycle.

Castelli, Michael G.↗
NASA NTRS2001

The Effect of Heat Treatment on Residual Stress and Machining Distortions in Advanced Nickel Base Disk Alloys

This paper describes an extension of NASA's AST and IDPAT Programs which sought to predict the effect of stabilization heat treatments on residual stress and subsequent machining distortions in the advanced disk alloy, ME-209. Simple "pancake" forgings of ME-209 were produced and given four heat treats: 2075F(SUBSOLVUS)/OIL QUENCH/NO AGE; 2075F/OIL QUENCH/1400F@8HR;2075F/OIL QUENCH/1550F@3HR/l400F@8HR; and 2160F(SUPERSOLVUS)/OIL QUENCH/1550F@3HR/ 1400F@8HR. The forgings were then measured to obtain surface profiles in the heat treated condition. A simple machining plan consisting of face cuts from the top surface followed by measurements of the surface profile opposite the cut were made. This data provided warpage maps which were compared with analytical results. The analysis followed the IDPAT methodology and utilized a 2-D axisymmetric, viscoplastic FEA code. The analytical results accurately tracked the experimental data for each of the four heat treatments. The 1550F stabilization heat treatment was found to significantly reduce residual stresses and subsequent machining distortions for fine grain (subsolvus) ME209, while coarse grain (supersolvus) ME209 would require additional time or higher stabilization temperatures to attain the same degree of stress relief.

Gayda, John↗
NASA NTRS2008

Weld Residual Stress and Distortion Analysis of the ARES I-X Upper Stage Simulator (USS)

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. While the main focus of this paper is a discussion of the weld modeling procedures and results for the USS, a short summary of the CIFS assessment is provided.

Raju, Ivatury↗
NASA NTRS2001

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

Malone, Tina W.↗
NASA NTRS2008

Ares I-X Upper Stage Simulator Residual Stress Analysis

The structural analyses described in the present report were performed in support of the NASA Engineering and Safety Center (NESC) Critical Initial Flaw Size (CIFS) assessment for the Ares I-X Upper Stage Simulator (USS) common shell segment. An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. The results of this effort served as one of the critical load inputs required to perform a CIFS assessment of the same segment.

Raju, Ivatury S.↗
NASA NTRS2013

Quantification of Residual Stress from Photonic Signatures of Fused Silica

A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outer-most pane of Space Shuttle windows made from fused silica. A method and apparatus for calibration of the stress-optic coefficient using four-point bending is discussed. The results are validated on known material (acrylic) and are found to agree with literature values to within 6%. The calibration procedure is then applied to fused-silica specimens and the stress-optic coefficient is determined to be 2.43 +/- 0.54 x 10(exp -12)/Pa. Fused silica specimens containing impacts artificially made at NASA's Hypervelocity Impact Technology Facility (HIT-F), to simulate damage typical during space flight, are examined. The damage sites are cored from fused silica window carcasses and examined with the GFP. The calibrated GFP measurements of residual stress patterns surrounding the damage sites are presented. Keywords: Glass, fused silica, photoelasticity, residual stress

Cramer, K. Elliott↗