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Results for “RESIDUAL STRESS”

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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Experimental determination of residual stress

Residual stresses in finished parts have often been regarded as factors contributing to premature part failure and geometric distortions. Currently, residual stresses in welded structures and railroad components are being investigated. High residual stresses formed in welded structures due primarily to the differential contractions of the weld material as it cools and solidifies can have a profound effect on the surface performance of the structure. In railroad wheels, repeated use of the brakes causes high residual stresses in the rims which may lead to wheel failure and possible derailment. The goals of the study were: (1) to develop strategies for using x-ray diffraction to measure residual stress; (2) to subject samples of Inconel 718 to various mechanical and heat treatments and to measure the resulting stress using x-ray diffraction; and (3) to measure residual stresses in ferromagnetic alloys using magnetoacoustics.

Ferguson, Milton W.↗
DOE OSTI2023

The high intensity diffractometer for residual stress analysis (HIDRA), a third generation residual stress mapping neutron diffractometer at the high flux isotope reactor

This paper describes the hardware and software upgrades, operation, and performance of the high intensity diffractometer for residual stress analysis (HIDRA) instrument, a residual stress mapping neutron diffractometer located at the High Flux Isotope Reactor at Oak Ridge National Laboratory in Oak Ridge Tennessee, USA. Following a major upgrade in 2018, the new instrument has a single 3 He multiwire 2D 30 × 30 cm 2 position sensitive detector, yielding a field of view of 17° 2θ. Further, the increase in the field of view (from 4° 2θ) from the previous model instrument has contributed to the tremendous improvement in the out of plane solid angle such that the 3D count rate could be obtained easily. Accordingly, the hardware, software, Data Acquisition System (DAS), and so on have also been updated. Finally, all these enhanced features of HIDRA have been ably demonstrated by conducting multi directional diffraction measurements in the quenched 750-T74 aluminum, and the evolved and improved strain/stress mappings are presented.

3D printing↗
DOE OSTI2018

Effect of Applied Stress and Temperature on Residual Stresses Induced by Peening Surface Treatments in Alloy 600

In this study, the effects of applied tensile stress and temperature on laser shock peening (LSP) and cavitation shotless peening (CSP)-induced compressive residual stresses were investigated using neutron and x-ray diffraction. Residual stresses on the surface, measured in situ, were lower than the applied stress in LSP- and CSP-treated Alloy 600 samples (2 mm thick). The residual stress averaged over the volume was similar to the applied stress. Compressive residual stresses on the surface and balancing tensile stresses in the interior relax differently due to hardening induced by LSP. Ex situ residual stress measurements, using XRD, show that residual stresses relaxed as the applied stress exceeded the yield strength of the LSP- and CSP-treated Alloy 600. Compressive residual stresses induced by CSP and LSP decreased by 15-25% in magnitude, respectively, on exposure to 250-450 °C for more than 500 h with 10-11% of relaxation occurring in the first few hours. Further, 80% of the compressive residual stresses induced by LSP and CSP treatments in Alloy 600 were retained even after long-term aging at 350 °C for 2400 h.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Residual stresses in Cu matrix composite surface deposits after laser melt injection

Abstract Tungsten carbide particles reinforced metal matrix composite (MMC) coatings can significantly improve surface wear resistance owing to their increased surface hardness. However, the presence of macro‐ and micro‐residual stresses in MMC coatings can have detrimental effects, such as reducing service life. In this study, neutron diffraction was used to determine the residual stresses in spherical fused tungsten carbide (sFTC) reinforced Cu matrix composite surface deposits after laser melt injection. We also developed a thermo‐mechanical coupled finite element model to predict residual stresses. Our findings reveal that sFTC/Cu composite deposits produced with a preheating temperature of 400°C have low residual stresses, with a maximum tensile residual stress of 98 MPa in the Cu matrix on the top surface. In contrast, the sFTC/bronze (CuAl10Ni5Fe4) composite deposit exhibits very high residual stresses, with a maximum tensile residual stress in the Cu matrix on the top surface reaching 651 MPa. These results provide a better understanding of the magnitudes and distributions of residual stresses in sFTC‐reinforced Cu matrix composite surface deposits manufactured via laser melt injection.

Zhang, Xingxing↗
DOE OSTI2021

Evaluation of residual stresses in isothermal friction stir welded 304L stainless steel plates

Friction stir welding was performed on 304L SS plates in order to heal simulated cracks created by electrical discharge machining. Two different tool temperatures (825 and 725 °C) were chosen for this study. Both neutron diffraction and X-ray diffraction techniques were employed to evaluate the residual stresses along two orthogonal reference directions, longitudinal (syy) and transverse (sxx). The former technique was also used to measure residual stresses at various depths. It was found that, at 1 mm depth from the top surface inside the stir zone (SZ), the longitudinal component was tensile in nature while the transverse component was compressive. The nature and magnitude of the residual stress fields, and the position of the peak residual stresses were found to vary with the weld depth. The SZ of the 725 °C weld exhibited higher peak stress than 825 °C weld mainly due to a lack of stress relief at the lower temperature.

Friction stir welding, Steel↗
DOE OSTI2024

Residual Stress in Cold Spray SS304L Measured Via Neutron Diffraction and Comparison of Analytical Models to Predict the Residual Stress

Here, this study employs neutron diffraction to investigate the relationship between residual stress and coating thickness in cold sprayed 304L austenitic stainless steel. Results show that shot peening predominantly impacts the residual stress profile, leading to substantial in-plane compressive force. The impact of laser heating, a widely used method to alter cold spray's microstructural properties, on the coating's residual stress is also analyzed. The findings indicate that the maximum compressive residual stress in the in-plane component is mainly independent of coating thickness, which suggests that the material properties determine the maximum residual stress. The cold sprayed deposits possessed compressive, nearly biaxial strain and stresses. After laser heating, these stresses were replaced by tensile residual stresses. Two analytical models, the Tsui and Clyne and the Boruah models, for predicting residual stresses are also evaluated, and both models provide reasonable fits to the experimental data. At this point, the deviations between the experimental results and the models are principally caused by the inability of the current models to address plastic deformation and relaxation, and the residual stresses generated by thermal gradients.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Residual Stress Modeling and Advanced Diffraction Measurements of 347H Steel Weldments

The 347H stainless steel is a primary high-temperature material for many energy and power generation industries. Stress relief cracking (SRC) has been a particular concern in welding of this material. The residual stress induced by welding and its evolution during post-welding heat treatment (PWHT) and subsequent operating and service conditions is one of the primary factors contributing to SRC. The lifetime of welded structure components is also controlled by the precipitation kinetics that accompanies PWHT, stress relaxation process, and long-term aging and complex synergistic factors. Various theories have been proposed in the past to explain SRC. However, a widely accepted approach to predicting the entire damage evolution and the resulting performance reduction is still lacking. This study is to demonstrate a reliable solution for two critical issues that affect the predictions. First, the residual stress distribution obtained from both simulation and neutron diffraction is compared, which increases the accuracy of mechanical analysis simulation model and therefore builds a solid basis for the lifetime prediction model. Second, the generation, evolution, and annihilation of precipitates are monitored by the synchrotron diffraction experiment. Preliminary results demonstrate the critical importance of precipitation kinetics on the residual stress distribution/redistribution during heat treatments.

Yang, Yi↗
DOE OSTI2019

Directional and oscillating residual stress on the mesoscale in additively manufactured Ti-6Al-4V Mesoscale and anisotropic residual stress in additive manufacturing of Ti-6Al-4V

In additive manufacturing of metals as compared to conventional processing, the directional track-by-track and layer-by-layer nature of the fabrication process can lead to residual stresses that locally are both directionally and spatially heterogeneous. Much of the existing literature has focused either on the macroscale residual stress inside the entire part, or on the microscale residual stresses that are created around a scan vector, thereby neglecting the intermediate length-scale of the different layers. The objective of this research is to investigate such mesoscale residual stress distributions across several layers in Ti-6Al-4V components produced by laser metal deposition process. The incremental centre hole drilling and incremental slitting methods provide measurements with excellent spatial resolution within and across the layer length scale. Here in this work, the two methods complemented each other to quantify both mesoscale and directional variations of residual stress that correlate with the deposition pattern. Lastly, our findings also provide strong evidence that an oscillatory residual stress variation persists even after thermal cycling that occurs during deposition of subsequent layers.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Beyond the Streetlight Effect: A United Future for Relaxation and Diffraction Methods for Residual Stress Measurement

Residual stress measurement techniques can be categorized as either relaxation or diffraction methods. Practitioners often advocate a particular category and sometimes a specific technique (hole drilling, contour, XRD, neutron, etc) based on their experience or capability rather than using the best technique for the particular application. This paper considers some of the implications from applying this “drunkard’s search” or “streetlight” approach by examining examples where the critical stress could be hidden from both relaxation and diffraction measurements. A better approach to planning residual stress measurements would begin with a detailed consideration of why the stresses should be measured and how the results will be used. Only then can the most appropriate measurement plan be developed. Since a single measurement technique cannot reveal the full state of stress, especially in challenging parts, the use of multiple measurement types often provides the most useful information to customers.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Evolution of residual stress, free volume, and hardness in the laser shock peened Ti-based metallic glass

Laser shock peening (LSP) with different cycles was performed on the Ti-based bulk metallic glasses (BMGs). The sub-surface residual stress of the LSPed specimens was measured by high-energy X-ray diffraction (HEXRD) and the near-surface residual stress was measured by scanning electron microscope/focused ion beam (SEM/FIB) instrument. The sub-surface residual stress in the LSP impact direction (about-170MPa) is much lower than that perpendicular to the impact direction (about -350 MPa), exhibiting anisotropy. The depth of the compressive stress zone increases from 400 mu m to 500 mu m with increasing LSP cycles. The highest near-surface residual stress is about -750 MPa. LSP caused the free volume to increase and the maximum increase appeared after the first LSP process. Compared with the hardness (567 +/- 7 HV) of the as-cast BMG, the hardness (590 +/- 9 HV) on the shocked surface shows a hardening effect due to the hardening mechanism of compressive residual stress; and the hardness (420 +/- 9 HV) on the longitudinal section shows a softening effect due to the softening mechanism of free volume.

bulk metallic glasses↗
DOE OSTI2019

Development of a Generalized Residual Stress Inversion Technique

Residual stress is a common result of manufacturing processes, but it is one that is often overlooked in design and qualification activities. There are many reasons for this oversight, such as lack of observable indicators and difficulty in measurement. Traditional relaxation-based measurement methods use some type of material removal to cause surface displacements, which can then be used to solve for the residual stresses relieved by the removal. While widely used, these methods may offer only individual stress components or may be limited by part or cut geometry requirements. Diffraction-based methods, such as X-ray or neutron, offer non-destructive results but require access to a radiation source. With the goal of producing a more flexible solution, this LDRD developed a generalized residual stress inversion technique that can recover residual stresses released by all traction components on a cut surface, with much greater freedom in part geometry and cut location. The developed method has been successfully demonstrated on both synthetic and experimental data. The project also investigated dislocation density quantification using nonlinear ultrasound, residual stress measurement using Electronic Speckle Pattern Interferometry Hole Drilling, and validation of residual stress predictions in Additive Manufacturing process models.

42 ENGINEERING↗
DOE OSTI2022

Why Is It So Challenging to Measure Residual Stresses ?

Abstract Background Residual stresses have a “hidden” character because they exist in a material without the presence of any external loads. They cannot easily be added or subtracted in a quantified manner, as is done when measuring applied stresses, and so are much more challenging to measure. Objective The objective here is to identify and describe the various features that make residual stress measurement methods challenging and to consider the ways that these challenges can be addressed in practice. Methods Various of the most common residual stress measurements methods are considered and the challenges associated with them are identified and classified. Results Five major challenges for residual stress measurements, and the approaches used for their resolution, are identified. Conclusions Despite the various challenges that need to be overcome, residual stress measurements can be successfully undertaken in practice. The most significant feature for success is a highly skilled and knowledge practitioner.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing

Large-scale additive manufacturing (AM) is of interest in the manufacturing industry to produce components of dimensions on the order of hundreds of millimeters to meters in scale. Wire-arc AM (WAAM) of Ti-6Al-4V (Ti64) is an attractive technique for large-scale AM in the aerospace industry, give the high strength-to-weight ratio of the material and high deposition rate of the process. However, due to the large scale, significant distortion and residual stresses are developed in the material during deposition and cooling, potentially leading to part failure. WAAM of a prototypical large-scale Ti64 machine tool component is studied in this work via finite element analysis (FEA). Element activation/deactivation technique is employed to simulate deposition and the resulting distortion and residual stress (RS) predictions are analyzed to evaluate the possibility of crack formation. Significant distortion (∼10 mm) and RS (>1300 MPa) is predicted, suggesting the formation of cracks and possible crack propagation into the build region. Incorporation of fillets significantly reduces RS concentration regions, thus reducing the possibility of part failure. Material deposition sequence also affects the RS pattern in the build.

Mathews, Ritin↗