Weld Characterization and Residual Stress Measurements for TC-128B Steel Plate

2002 ◽  
Vol 124 (4) ◽  
pp. 405-414 ◽  
Author(s):  
M. A. Sutton ◽  
I. Abdelmajid ◽  
W. Zhao ◽  
D. Wang ◽  
C. Hubbard
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Fatigue Cracks ◽  
Three Dimensional ◽  
Base Material ◽  
Shear Stresses ◽  
Residual Stress Field ◽  
Weld Region ◽  
Longitudinal Residual Stress ◽  
Transverse Weld

Welding is the primary joining process used in the construction and repair of railroad tank cars. Since recent federal regulations have emphasized the need for fatigue life analyses, and since most fatigue cracks and fractures in tank car structures are initiated in the vicinity of welds, there is a need to quantify the effect of tank car weld residual stresses on crack propagation and fracture. Thus, for the first time, the enclosed work reports neutron diffraction results for all six components of the three-dimensional residual stress field on a transverse weld cross section in a 5/8-in. (16.3-mm) thick, TC128-B steel widely used in the construction of pressurized railroad tank cars. Results for a nonheat- treated specimen indicate that (a) the residual effective stress ranges from 36 ksi (250 MPa) to 64 ksi (450 MPa) in the overmatched weld region, (b) the longitudinal residual stress approaches 120% of the uniaxial yield stress in the base material, and (c) the residual shear stresses are of the same order as the smaller principal residual stresses in the weld region.

The Influence of Chemical Composition on Residual Stresses in NiCoMo Alloy Deposits on 12 Ni Maraging Steel

2013 ◽  
Vol 768-769 ◽  
pp. 449-455 ◽  
Author(s):  
Zoran Bergant ◽  
Janez Grum
Keyword(s):  
Residual Stress ◽  
Chemical Composition ◽  
Residual Stresses ◽  
Base Material ◽  
Stress Generation ◽  
Hole Drilling ◽  
Residual Stress Field ◽  
Hole Drilling Method ◽  
Similar Chemical ◽  
Drilling Method

The in-plane residual stresses in laser cladded specimens, made of 12-nickel precipitation hardening maraging hot-working tool steel 1.2799 (SIST EN 10027-2) are analyzed using the hole drilling method. The CO2 laser was used to deposit the alloy NiCoMo-1 with significantly higher content of nickel and cobalt with austenitic microstructure at room temperature. The Nd:YAG laser was used to deposit the maraging alloy designated NiCoMo-2, with similar chemical composition as the base material. The comparison of residual stress field showed the sign and the magnitude of residual stresses depends on the chemical composition of the clad being deposited. The high tensile residual stresses were found in NiCoMo-1 layers and favorable compressive residual stresses were found in NiCoMo-2 layers. The metallurgical aspects of residual stress generation are discussed.

Deformation State Evaluation Around Deep Drilled Hole After Three-Dimensional Stress Release

2011 ◽  
Author(s):  
Houichi Kitano ◽  
Shigetaka Okano ◽  
Masahito Mochizuki
Keyword(s):  
Residual Stresses ◽  
Three Dimensional ◽  
Hole Drilling ◽  
Shear Stresses ◽  
Accuracy Evaluation ◽  
Thickness Direction ◽  
Stress Release ◽  
Residual Stress Field ◽  
Theoretical Approaches ◽  
Deformation State

Deep hole drilling technique (DHD) has received much attention as a method for measurements of thorough thickness residual stresses in recent years. In the past, however, the measurements of residual stresses by DHD technique have been limited to evaluation for in-plane stress and stress in through thickness direction. In the present study, the effect of shear stresses in through thickness direction on deformation states around the through thickness hole after stress release is discussed by theoretical approaches. In addition, the method for evaluating shear stresses in cutting direction is proposed from the result obtained by the previous theoretical investigation. Then, an unequal three-dimensional residual stress field is evaluated by DHD (or iDHD) technique and the proposed method using measurement changes obtained by numerical analysis. Finally, the reasons why the differences between the evaluation results and the stress distributions on the center line of the trepanned core are exits are clarified for high-accuracy evaluation.

scholarly journals Finite Element Estimation of the Residual Stresses in Roller-Straightened Rail

2004 ◽  
Author(s):  
Brandon Talamini ◽  
Jeff Gordon ◽  
A. Benjamin Perlman
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Relative Influence ◽  
Stress Profile ◽  
Residual Stress Field ◽  
3 Dimensional ◽  
Longitudinal Residual Stress ◽  
Final Profile

The purpose of this paper is to develop models to accurately predict the residual stresses due to the roller straightening of railroad rails. Several aspects of residual stress creation in rail due to roller straightening are addressed. The effect of the characteristics of the loads applied by the roller-straightener on the stress profile is examined. In addition, the analysis attempts to discern the relative influence of bending and contact on the residual stresses. The last goal is to determine how the heat treatment of rail alters the predicted roller-straightening residual stress field. The loads for the simulation are estimated from available data. To identify the most credible values, a baseline loading case is defined and modeled. These straightening loads are parameterized by considering alternative loading scenarios. Residual stresses and deformations are calculated using these loads. To separate the effects of bending and contact on the residual stress induced by the roller loads, each credible load case is analyzed with two models. One is a 2-dimensional generalized plane strain (GPS) model that accounts only for the flexural stresses. The other is a fully 3-dimensional analysis that includes roll-on-rail contact to make estimates of the true residual stress field. Comparison of the residual stress results from both models reveals the relative influence of local roll-rail contact and bending on the final profile. Comparison of the 2- and 3-dimensional residual stress results reveals that the magnitude of the contact loads is a decisive influence on the stress field, even in portions of the rail web located far from the contact interface. Therefore, it is critical to obtain accurate estimates of the straightening loads to make accurate roller straightening residual stress estimates. Heat treatment of the rail prior to roller straightening primarily affects the longitudinal residual stress in the web, causing a positive shift in the stress values.

Numerical Simulation of Residual Stresses Due to Cladding Process

2007 ◽  
Author(s):  
Dieter Siegele ◽  
Marcus Brand
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Finite Element ◽  
Stress Field ◽  
Residual Stresses ◽  
Base Metal ◽  
Base Material ◽  
Pressure Vessels ◽  
Measured Temperature ◽  
Residual Stress Field

The inner surface of reactor pressure vessels is protected against corrosion by an austenitic cladding. Generally, the cladding is welded on the ferritic base metal with two layers to avoid sub-clad cracks and to improve the microstructure of the cladding material. On the other hand, due to the cladding process and the difference of the thermal expansion coefficient of the austenitic cladding and the ferritic base material residual stresses act in the component. This residual stress field is important for assessing crack postulates in the cladding or subclad flaws in the base metal. For the determination of the residual stress field, plates of RPV steel were cladded and heat treated representative to the RPV relevant conditions. During the cladding process the temperature and distortion were measured as basis for the validation of the finite element simulations. The numerical simulation was performed with the finite element code SYSWELD. The heat source of the model was calibrated on the measured temperature profile. In the analysis, the temperature dependent material properties as well as the transformation behavior of the ferritic base metal were taken into account. The calculated residual stresses show tensile stresses in the cladding followed by compressive stresses in the base metal that are in agreement with measurements with X-ray diffraction technique.

scholarly journals Residual stress redistribution during elastic shake down in welded plates

2018 ◽  
Vol 165 ◽  
pp. 21004
Author(s):  
Jazeel R. Chukkan ◽  
Guiyi Wu ◽  
Michael E. Fitzpatrick ◽  
Elvin Eren ◽  
Xiang Zhang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Base Material ◽  
Offshore Structures ◽  
Residual Stress Field ◽  
Mixed Hardening ◽  
Weld Residual Stress ◽  
Shakedown Limit ◽  
Elastic Shakedown ◽  
Different Levels

Residual stresses are a consequence of welding in various structures such as ships and offshore structures. Residual stresses can be relaxed or redistributed according to the load levels during operation. The elastic shakedown phenomenon can be considered as one of the reasons for this change. This paper studies the relaxation/redistribution of weld residual stress during different levels of shakedown in a butt-welded plate chosen according to ship design and welding procedures. Welding was performed on DH36, a ship structural steel. Neutron diffraction was used to measure residual stresses in these plates in the as-welded state and after different levels of shakedown. A mixed hardening model in line with the Chaboche model is determined for both weld and base material. A numerical model is developed to estimate the shakedown limit on butt-welded plate. Further, the redistribution of residual stress in a numerical weld model according to the different levels of shakedown limit is studied. Based on the shakedown limit of the butt-welded plate, a shakedown region is determined, where the structure will undergo elastic shakedown in the presence of an existing residual stress field if the maximum stress on the load section after a few initial cycles is in the shakedown region.

Multipass low-plasticity burnishing induced residual stresses: Three-dimensional elastic-plastic finite element modelling

2004 ◽  
Vol 218 (6) ◽  
pp. 663-668 ◽  
Author(s):  
W Zhuang ◽  
B Wicks
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stress Field ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Three Dimensional ◽  
Element Model ◽  
Residual Stress Field ◽  
Moving Contact ◽  
Low Plasticity Burnishing

Low-plasticity burnishing (LPB) is a surface modification process involving complex cyclic plastic deformation that results in the development of a deep residual stress field. In order to achieve an optimal LPB-induced residual stress field for the geometry appropriate to the aircraft engine component, the key parameters of the LPB process, such as burnishing load, burnishing ball size and material properties, need to be determined. For this purpose, a three-dimensional non-linear moving contact finite element model is proposed to simulate the multipass LPB process and to predict the effects of those parameters on the resultant residual stress field. The material constitutive model used in the finite element analysis has been developed from the cyclic stress/strain response obtained from experimental measurements on the material. Prediction of the LPB-induced residual stresses by the finite element model appears to agree reasonably well with X-ray diffraction measurements.

Relaxation of Peening Residual Stresses Due to Cyclic Thermo-Mechanical Overload

2005 ◽  
Vol 127 (2) ◽  
pp. 170-178 ◽  
Author(s):  
S. A. Meguid ◽  
G. Shagal ◽  
J. C. Stranart ◽  
K. M. Liew ◽  
L. S. Ong
Keyword(s):  
Residual Stress ◽  
Cyclic Loading ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Target Material ◽  
High Strength ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Strain Rate Effects ◽  
Multiple Impact

Shot-peening induced residual stresses can be relaxed due to cyclic loading. This relaxation plays an important role in determining the fatigue life of the peened components. It is therefore the purpose of this study to conduct comprehensive three-dimensional dynamic elasto-plastic finite element analysis of the joint peening treatment and relaxation process. In this regard, a novel symmetry cell is developed and used to model the multiple impact indentations resulting from multiple impingements of a cluster of shots. The model was further extended to integrate the relaxation resulting from cyclic loading at stresses above the yield strength of the material. This integrated model accounts for the main features of both stages by considering strain-rate effects, shot and target inertia and the dependence of the mechanical properties of the target material on temperature. A wide spectra of cyclic mechanical and thermal loads as well as their combinations is considered and the resulting relaxed residual stress field is determined. As an application, the model was used to predict the residual stress relaxation in a high-strength steel target made from AISI 4340 under different peening and thermomechanical cyclic overload.

FEM Prediction of Welding Residual Stresses and Temperature Fields in Butt and T-Welded Joints

2011 ◽  
Vol 418-420 ◽  
pp. 1486-1493
Author(s):  
Afsaneh Razavi ◽  
Fatemeh Hafezi ◽  
Hossein Farrahi
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joints ◽  
Parametric Design ◽  
Weld Zone ◽  
Three Dimensional ◽  
Welding Process ◽  
Temperature Fields ◽  
Residual Stress Field ◽  
Welding Processes

Residual stresses resulted from localized non-uniform heating and subsequent cooling during welding processes enact an important role in the formation of cracks and welding distortions and have severe effect on performance of welded joints. The present research performs a three dimensional transient thermo Elasto-plastic analysis using finite element technique to simulate welding process. Welding simulation procedure is developed using the parametric design language of commercial code ANSYS for single pass T and butt welded joints. The procedure verified with predicted residual stress field found in literature to confirm the accuracy of the method. The material of the weld metal, HAZ and the base metal are assumed to be the same. With regards to high temperature gradient in weld zone, temperature dependant thermal and mechanical properties have been incorporated in the simulation. Also in this work the technique of element birth and death was employed to simulate moving heat source and the weld filler variation with time. Temperature and residual stress fields were discussed.

Residual stresses in alumino-thermic welded rails

1997 ◽  
Vol 32 (6) ◽  
pp. 389-400 ◽  
Author(s):  
P J Webster ◽  
G Mills ◽  
X D Wang ◽  
W P Kang ◽  
T M Holden
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Surface Defects ◽  
Fatigue Cracks ◽  
Operating Experience ◽  
Stress Fields ◽  
Residual Stress Field ◽  
Initiation And Propagation ◽  
Longitudinal Residual Stress ◽  
The Web

Neutron strain scanning has been used to map the residual stress field that is generated in a railway rail by a standard gap alumino-thermic weld made using routinely specified procedures. The longitudinal and vertical residual stress fields in the sections well away from the weld are characteristic of many unwelded rails, being generally tensile in the head and foot with balancing compression in the web. In the vicinity of the weld the residual stress patterns are very different. At the top and bottom surfaces of the rail the longitudinal residual stress field is strongly compressive, which is generally beneficial in that it would tend to inhibit the initiation and propagation of fatigue cracks from surface defects. Just at the surface the vertical residual stress attenuates to zero but internally, in the web region, both longitudinal and vertical components of the residual stress field are strongly tensile, which increases the susceptibility of that region to crack initiation and propagation from internal material defects. This pattern is consistent with practical operating experience, which is that most of the small proportion of alumino-thermic welds that do fail do so as a result of porosity or inclusions in the weld. It is found that the ‘boundaries’ of the ‘weld type’ residual stress fields do not coincide with the boundary of the weld, nor of the heat-affected zone, but correlate reasonably well with the positions of the extremities of the mould assembly and with the location of the steepest longitudinal temperature gradients.

Measurement of Residual Stresses in Linear Friction Welded In-Service Inconel 718 Superalloy

2016 ◽  
Vol 879 ◽  
pp. 1800-1806 ◽  
Author(s):  
M. Smith ◽  
L. Bichler ◽  
D. Sediako
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Base Material ◽  
Peak Stress ◽  
Weld Interface ◽  
Aerospace Alloys ◽  
Aero Engine ◽  
Linear Friction ◽  
Inconel 718 Superalloy ◽  
Residual Strains

Measurement of residual strains by neutron diffraction of linear friction welded Inconel® 718 (IN 718) superalloy acquired from a mid-service aero-engine disk was undertaken in this study. Residual strain and stress throughout the various weld regions including the heat affected zone (HAZ), thermomechanical affected zone (TMAZ) and dynamically recrystallized zone (DRX) were characterized. The residual stresses were observed to increase from the base material to the weld interface, with a peak stress at the weld interface in all orthogonal directions. The trends for residual stress across the weld are in agreement with other work published in literature for solid state welding of aerospace alloys, where high residual stresses were commonly reported at the weld interface.

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