Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “RESIDUAL STRESSES”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Determination of Stress-Free Lattice Spacing (D₀) for Residual Stress Relaxation Measurement in Ni-based Superalloys by Neutron Diffraction

The residual stress and its relaxation in critical engineering components are key to structural materials reliability. The determination of residual stress in bulk engineering structures like Ni-based superalloys can be conducted by measuring the lattice strain with penetrating neutron diffraction. The state-of-the-art engineering diffraction beamline VULCAN at the Oak Ridge National Laboratory (ORNL) Spallation Neutron Source (SNS) provides the critical capability to evaluate the residual strain/stress relaxation in engineering component thanks to the high flux and event data features. By the means of residual stress/strain calculation, it is critical to accurately determine the stress-free lattice spacing d₀, which can be altered by the change of chemistry, unrelieved stress, and measurement scheme. Here we reported d₀ determination for determining residual stress relaxation and distribution in Alloy 718 superalloys after different quenching treatments. Selection of locations for d₀ measurement was discussed by considering the neutron path, attenuation and sample alignment. A dynamic d₀ that resulted from atom diffusion and chemistry change was estimated as function of time for the in-situ relaxation characterization. It demonstrated how the dynamic d₀ values may influence on the strain calculation in different thermally treated samples. The results highlight the importance of dynamic d₀ for in-situ relaxation involving chemical changes and provide guidance to the dynamic d₀ measurement and simulation.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Three-dimensional local residual stress and orientation gradients near graphite nodules in ductile cast iron [3D local residual stress and orientation gradients near graphite nodules in ductile cast iron]

A synchrotron technique, differential aperture X-ray microscopy (DAXM), has been applied to characterize the microstructure and analyze the local mesoscale residual elastic strain fields around graphite nodules embedded in ferrite matrix grains in ductile cast iron. Compressive residual elastic strains are measured with a maximum strain of ~6.5–8 × 10 –4 near the graphite nodules extending into the matrix about 20 μm, where the elastic strain is near zero. The experimental data are compared with a strain gradient calculated by a finite element model, and good accord has been found but with a significant overprediction of the maximum strain. This is discussed in terms of stress relaxation during cooling or during storage by plastic deformation of the nodule, the matrix or both. Furthermore, relaxation by plastic deformation of the ferrite is demonstrated by the formation of low energy dislocation cell structure also quantified by the DAXM technique.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Relaxation of bending stresses and the reversibility of residual stresses in amorphous soft magnetic alloys

The reversibility of residual bending stresses is revealed in ribbon samples of cobalt- and iron-based amorphous alloys Co{sub 69}Fe{sub 3.7}Cr{sub 3.8}Si{sub 12.5}B{sub 11} and Fe{sub 57}Co{sub 31}Si{sub 2.9}B{sub 9.1}: the ribbons that are free of applied stresses and bent under the action of residual stresses become completely or incompletely straight upon annealing at the initial temperatures. The influence of annealing on the relaxation of bending stresses is studied. Preliminary annealing is found to sharply decrease the relaxation rate of bending stresses, and the initial stage of fast relaxation of these stresses is absent. Complete straightening of preliminarily annealed ribbons is shown to occur at significantly higher temperatures than that of the initial ribbons. Incomplete straightening of the ribbons is explained by the fact that bending stresses relaxation at high annealing temperatures proceeds due to both reversible anelastic deformation and viscous flow, which is a fully irreversible process. Incomplete reversibility is also caused by irreversible processes, such as the release of excess free volume and clustering (detected by small-angle X-ray scattering). The revealed differences in the relaxation processes that occur in the cobalt- and iron-based amorphous alloys are discussed in terms of different atomic diffusion mobilities in these alloys.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

The relationships between residual stress relaxation and texture development in AZ31 Mg alloys via the vibratory stress relief technique

A systematic study of residual stress relaxation and the texture evolution of cold-rolled AZ31 Mg alloys using the vibratory stress relief technique with a simple cantilever beam vibration system was performed using a high-resolution X-ray diffractometer and a portable X-ray residual stress analyzer. The effects of vibrational stress excitation on the surface residual stress distribution and on the texture of pole figures (0002) occurring during the vibratory stress relief were examined. Compared with the effects corresponding to the same alloy under non-vibration condition, it can be observed that the uniform surface residual stress distribution and relaxation of the compressive residual stress in the stress concentration zone were observed rather than all of the residual stresses being eliminated. Furthermore, with an increase in the vibrational aging time, the compressive residual stress, texture density, and (0002) preferred orientation increased first and then decreased. It should be underlined that the vibratory stress relief process for the vibrational aging time of more than 10 min is able to weaken the strong basal textures of AZ31 Mg alloys, which is valuable for enhancement of their formability and is responsible for an almost perfect 3D-Debye–Scherrer ring. - Highlights: • 3D-Debye ring about VSR technique is not discussed in the existing literature. • A newly developed VSR method is suitable for small or thin workpieces. • The cosα method accurately and effectively determines the residual stresses. • The VSR technique is valuable for enhancement of their formability. • The texture and preferred orientation change with the vibrational aging time.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Gyrokinetic simulation of momentum transport with residual stress from diamagnetic level velocity shears

Residual stress refers to the remaining toroidal angular momentum (TAM) flux (divided by major radius) when the shear in the equilibrium fluid toroidal velocity (and the velocity itself) vanishes. Previously [Waltz et al., Phys. Plasmas 14, 122507 (2007); errata 16, 079902 (2009)], we demonstrated with GYRO [Candy and Waltz, J. Comp. Phys. 186, 545 (2003)] gyrokinetic simulations that TAM pinching from (ion pressure gradient supported or diamagnetic level) equilibrium ExB velocity shear could provide some of the residual stress needed to support spontaneous toroidal rotation against normal diffusive loss. Here we show that diamagnetic level shear in the intrinsic drift wave velocities (or ''profile shear'' in the ion and electron density and temperature gradients) provides a comparable residual stress. The individual signed contributions of these small (rho-star level) ExB and profile velocity shear rates to the turbulence level and (rho-star squared) ion energy transport stabilization are additive if the rates are of the same sign. However because of the additive stabilization effect, the contributions to the small (rho-star cubed) residual stress is not always simply additive. If the rates differ in sign, the residual stress from one can buck out that from the other (and in some cases reduce the stabilization.) The residual stress from these diamagnetic velocity shear rates is quantified by the ratio of TAM flow to ion energy (power) flow (M/P) in a global GYRO core simulation of a ''null'' toroidal rotation DIII-D [Mahdavi and Luxon, Fusion Sci. Technol. 48, 2 (2005)] discharge by matching M/P profiles within experimental uncertainty. Comparison of global GYRO (ion and electron energy as well as particle) transport flow balance simulations of TAM transport flow in a high-rotation DIII-D L-mode quantifies and isolates the ExB shear and parallel velocity (Coriolis force) pinching components from the larger ''diffusive'' parallel velocity shear driven component and the much smaller profile shear residual stress component.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

Verification and validation of residual stresses in composite structures

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, the objectives of the presented work are to demonstrate an efficient method for simulating residual stresses in composite parts, as well as the potential value of statistical methods during analyses for which material properties are unknown. Specifically, a simplified residual stress modeling approach is implemented within Sandia National Laboratories’ SIERRA/SolidMechanics code. Concurrent with the model development, bi-material composite structures are designed and manufactured to exhibit significant residual stresses. Then, the presented modeling approach is rigorously verified and validated through simulations of the bi-material composite structures’ manufacturing processes, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.

42 ENGINEERING↗
DOE OSTI2020

Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here we report an initial reproducibility experiment focused on contour method data analysis and residual stress calculation. The experiment uses surface topography data from a physical process simulation of elastic-plastic beam bending. The simulation provides surface topography, for input to the contour method data analysis, as well as a known residual stress field with 130 MPa peak magnitude. Additionally, to increase realism, noise and specific artifacts are added to the topography data. A group of participants received the topography data (without the known residual stress), independently analyzed the data, and submitted results as a two-dimensional residual stress field. Analysis of submissions provides a group average residual stress field and the spatial distribution of reproducibility standard deviation. The group average residual stress agrees with the known stress in magnitude and spatial trend. The reproducibility standard deviation ranges from 2 to 54 MPa over the measurement plane, with an average of 5.4 MPa. Reproducibility standard deviation is smaller in the cross-section interior (≤ 5 MPa), modest near local extrema in the stress field (5 to 10 MPa), and larger near the cross-section boundaries (10 to 30 MPa). Overall, the largest values of reproducibility standard deviation (up to 54 MPa) occur in limited areas where artifacts had been added to the topography data; while some participants identified and removed these artifacts, some did not, leading to systematic differences that elevated the standard deviation.

42 ENGINEERING↗
DOE OSTI2015

High-Temperature Deformation Constitutive Law for Dissimilar Weld Residual Stress Modeling: Effect of Thermal Load on Strain Hardening

Weld residual stress is one of the primary driving forces for primary water stress corrosion cracking in dissimilar metal welds (DMWs). To mitigate tensile residual stress in DMWs, it is critical to understand residual stress distribution by modeling techniques. Recent studies have shown that weld residual stress prediction using today s DMW residual stress models strongly depends on the strain-hardening constitutive model chosen. The commonly used strain-hardening models (isotropic, kinematic, and mixed) are all time-independent and inadequate to account for the time-dependent (viscous) plastic deformation at the elevated temperatures experienced during welding. For materials with profound strain-hardening, such as stainless steels and nickel-based alloys that are widely used in nuclear reactor and piping systems, the equivalent plastic strain the determinate factor of the flow stress can be highly dependent on the recovery and recrystallization processes. These processes are in turn a strong function of temperature, time, and deformation rate. Recently, the authors proposed a new temperature- and time-dependent strain-hardening constitutive model: the dynamic strain-hardening constitutive model. The application of such a model has resulted in improved weld residual stress prediction compared to the residual stress measurement results from the contour and deep-hole drilling methods. In this study, the dynamic strain-hardening behavior of Type 304 stainless steel and Alloy 82 used in pressure vessel nozzle DMWs is experimentally determined. The kinetics of the recovery and recrystallization of flow stress are derived from experiments, resulting in a semi-empirical equation as a function of pre-strain, time, and temperature that can be used for weld residual stress modeling. The method used in this work also provides an approach to study the kinetics of recovery and recrystallization of other materials with significant strain-hardening.

Yu, Xinghua↗
DOE OSTI2010

Elastoplastic analysis of process induced residual stresses in thermally sprayed coatings

The residual stresses induced from thermal spraying process have been extensively investigated in previous studies. However, most of such works were focused on the elastic deformation range. In this paper, an elastoplastic model for predicting the residual stresses in thermally sprayed coatings was developed, in which two main contributions were considered, namely the deposition induced stress and that due to differential thermal contraction between the substrate and coating during cooling. The deposition induced stress was analyzed based on the assumption that the coating is formed layer-by-layer, and then a misfit strain is accommodated within the multilayer structure after the addition of each layer (plastic deformation is induced consequently). From a knowledge of specimen dimensions, processing temperatures, and material properties, residual stress distributions within the structure can be determined by implementing the model with a simple computer program. A case study for the plasma sprayed NiCoCrAlY on Inconel 718 system was performed finally. Besides some similar phenomena observed from the present study as compared with previous elastic model reported in literature, the elastoplastic model also provides some interesting features for prediction of the residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Residual stress in spin-cast polyurethane thin films

Residual stress is inevitable during spin-casting. Herein, we report a straightforward method to evaluate the residual stress in as-cast polyurethane thin films using area shrinkage measurement of films in floating state, which shows that the residual stress is independent of radial location on the substrate and decreased with decreasing film thickness below a critical value. We demonstrate that the residual stress is developed due to the solvent evaporation after vitrification during spin-casting and the polymer chains in thin films may undergo vitrification at an increased concentration. The buildup of residual stress in spin-cast polymer films provides an insight into the size effects on the nature of polymer thin films.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗