Characterization of the Residual Stresses and Strength of Ceramic-Metal Braze Joints

2009 ◽  
Vol 131 (2) ◽  
Author(s):  
Matteo Galli ◽  
John Botsis ◽  
Jolanta Janczak-Rusch ◽  
Gerd Maier ◽  
Udo Welzel
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Finite Element Models ◽  
Plastic Response ◽  
X Ray Diffraction ◽  
Elastoplastic Properties ◽  
Bend Tests ◽  
Point Bend ◽  
Good Agreement

Residual stress relief in ceramic-metal joints produced by active brazing depends primarily on the plastic response of the filler metal. A procedure for the production and mechanical characterization of bulk active filler alloy specimens is developed. In parallel ceramic-metal joints are produced and tested. Residual stresses are measured by X-ray diffraction while the joint strength is assessed by four-point bend tests. The obtained elastoplastic properties of the filler are introduced into finite element models to predict the residual stresses in the joints and their behavior in bending. The results of the simulations show good agreement both with the residual stress measurements and with the results of four-point bend tests.

Residual stresses in spray-formed A2 tool steel

1999 ◽  
Vol 14 (12) ◽  
pp. 4521-4530 ◽  
Author(s):  
H. M. Hu ◽  
E. J. Lavernia ◽  
Z. H. Lee ◽  
D. R. White
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Tool Steel ◽  
Spray Forming ◽  
Substrate Material ◽  
X Ray Diffraction ◽  
Displacement Fields ◽  
X Ray ◽  
Commercial Code ◽  
Good Agreement

The objective of this work was to investigate the fundamental factors that govern the formation and magnitude of residual stresses in A2 tool steel fabricated using spray-forming techniques. To that effect, a finite-element method (FEM) was performed by using a commercial code, ABAQUS, to solve for the temperature and displacement fields. Moreover, the residual stresses in the spray-formed materials were measured using x-ray diffraction to compare the FEM results with experimentation. Two types of substrate material, copper and Rescor™ 780 cer-cast ceramic, were used to investigate the influence of heat conduction on residual stress in the preforms. Relatively good agreement was found between experimentation and theory. The results show that the residual stress varies greatly with the position in deposited preform and that heat-transfer coefficient at the interface of spray-formed material/substrate affects the distribution and magnitude of the residual stresses significantly.

Magnetic Barkhausen Measurements for Determining Residual Stress Distribution in Welded Electrical Steels

2016 ◽  
Vol 856 ◽  
pp. 147-152 ◽  
Author(s):  
Polykseni Vourna ◽  
Aphrodite Ktena ◽  
Athanasios G. Mamalis ◽  
Evangelos Hristoforou ◽  
Peng Wan Chen ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Residual Stresses ◽  
Electron Beam Welding ◽  
Research Work ◽  
Calibration Procedure ◽  
Residual Stress Distribution ◽  
X Ray Diffraction ◽  
Electrical Steels ◽  
Good Agreement

In the present research work the determination of residual stress distribution in welded non-oriented electrical steel samples is discussed. Tungsten Inert Gas and Electron Beam Welding were used as the welding methods. The residual stresses induced by welding estimated by the magnetic, non-destructive method of Barkhausen noise and were compared with the values resulting from the semi-destructive method of X-ray diffraction Bragg-Brentano (XRD-BB). In order to evaluate accuracy and reliability of the magnetic methods applied, the steel samples were subjected in both compressive and tensile stress and the magnetic noise values were correlated to residual stress values through an appropriate calibration curve. Furthermore, the fluctuations of the residual stresses in the welding zones of the welded samples were discussed on the basis of the experimental evidence and the microstructural changes occurring during welding. It was found that the residual stress determined by MBN method was in good agreement with the XRD-BB results. However, the residual stress determined by magnetic permeability method was not in good agreement with the XRD-BB results. In contrast to the XRD-BB method, the magnetic techniques required a precise calibration procedure in all zones with noticeably different microstructure.

Temperature Dependence of Residual Stress Gradients in Shot-Peened Steel Coated with CrN

2008 ◽  
Vol 571-572 ◽  
pp. 101-106 ◽  
Author(s):  
Klaus J. Martinschitz ◽  
C. Kirchlechner ◽  
R. Daniel ◽  
G. Maier ◽  
C. Mitterer ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Temperature Dependence ◽  
X Ray Diffraction ◽  
Stress Gradients ◽  
Coated Tools ◽  
Micro Cracks ◽  
Depth Gradients

A temperature behaviour of residual stresses in shot-peened steel coated with 3m CrN is characterized using in-situ energy dispersive synchrotron X-ray diffraction performed in the temperature range of 25-800°C. The samples are thermally cycled and the development of volumeaveraged residual stresses in the coating and residual stress depth gradients in the steel is characterized. The results reveal complex changes of stresses in CrN and in the substrate. The annealing results in the removal of stress gradients in the steel which starts at the temperature of about 600°C. After cooling down, there are no stresses detected in the steel. The temperature dependence of stresses in CrN is very complex and indicates the presence of phenomena like an annealing of intrinsic stresses about the deposition temperature of 350°C, a formation and a closing of micro-cracks in the tensile region and finally a stress relaxation of approximately 500 MPa after the cooling down. The presented approach allows a complex characterization of thermo-mechanical processes in coating-substrate composites and opens the possibility to understand phenomena related to the thermal fatigue of coated tools.

Characterization of Bolt Hole Residual Stresses for Assessing Structural Behavior of Truck Frame Rails

2011 ◽  
Vol 418-420 ◽  
pp. 1124-1131
Author(s):  
K. Chinnaraj ◽  
M. Sathya Prasad ◽  
C. Lakshmana Rao
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Initial Conditions ◽  
Fatigue Cracks ◽  
Structural Behavior ◽  
X Ray Diffraction ◽  
Water Jet Cutting ◽  
Large Numbers ◽  
Bolt Holes

Chassis frame rails in a truck are load bearing structural members that integrate vehicle power train with superstructure to form a complete vehicle. Large numbers of bolt holes that are cut into these frame side members act as joineries and points of attachments for various sub systems of the truck. While bolt holes are unavoidable due to its primary functional importance, the near hole residual stresses remaining from hole cutting operations may play a significant role in deciding the life of frame rail sections as they lead to early initiation of fatigue cracks around bolt hole surface. In order to assess the extent of plastic deformation and resulting residual stress pattern in near hole areas of bolt holes, experimental investigation through microstructure analysis, micro-hardness and X-ray diffraction measurements has been taken up. The hole cutting operations considered for this exercise are drilling, punching, laser cutting and water jet cutting used to cut holes on truck frame rail sections. Apart from this, an assessment of shot-peened hole surface was also taken up to understand the effect of shot-peening on structural behavior of frame rail bolt hole sections. The experimentally measured near hole residual stress profiles can be considered as initial conditions for further numerical analysis to study the influence of bolt hole residual stresses on fatigue life of frame rail sections.

Investigations on Physical and Mechanical Characterization of the Joints Fabricated through Microwave Hybrid Heating Method

2021 ◽  
Vol 105 ◽  
pp. 25-41
Author(s):  
Parminder Singh ◽  
D.R. Prajapati ◽  
Shankar Sehgal
Keyword(s):  
Power Level ◽  
Dissimilar Materials ◽  
Hardness Test ◽  
Optical Microscope ◽  
X Ray Diffraction ◽  
Heating Method ◽  
Hybrid Heating ◽  
Microwave Hybrid Heating ◽  
Point Bend

This paper presents the current major research developments and growths in the area of microwave hybrid heating-based joining of similar and dissimilar materials. The study discusses on the different types of specimen materials, susceptor materials, fillers and microwave power level used by researchers for joining process. Comparative studies of joints using different parametric conditions are also mentioned. Physical characterization of joint has been investigated with optical microscope, scanning electron microscope, energy dispersive spectroscopy, electron probe micro analysis, X-ray diffraction and mechanically with hardness test, tensile test, 3-point bend test, impact test. Various methods for design of experiment and optimization are also used to obtain better results. Current study will facilitate the proper choice of input parameters for easy and good joints formation through the microwave hybrid heating method.

scholarly journals Strategy of Residual Stress Determination on Selective Laser Melted Al Alloy Using XRD

Materials ◽  
2020 ◽  
Vol 13 (2) ◽  
pp. 451 ◽  
Author(s):  
Yujiong Chen ◽  
Hua Sun ◽  
Zechen Li ◽  
Yi Wu ◽  
Yakai Xiao ◽  
...  
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Residual Stresses ◽  
High Surface ◽  
Al Alloy ◽  
X Ray Diffraction ◽  
Scanning Strategy ◽  
Surface Distribution ◽  
Finished Surface ◽  
Microstructural Morphology

Selective laser melting (SLM) is known to generate large and anisotropic residual stresses in the samples. Accurate measurement of residual stresses on SLM-produced samples is essential for understanding the residual stress build-up mechanism during SLM, while a dramatic fluctuation can be observed in the residual stress values reported in the literature. On the basis of studying the influence of surface roughness on residual stress measured using X-ray diffraction (XRD), we propose a procedure coupling XRD technique with pretreatment consisting of mechanical polishing and chemical etching. The results highlight that residual stresses measured using XRD on as-built SLM-produced samples with high surface roughness are significantly lower than those measured on samples with finished surface, which is due to the stress relaxation on the spiked surface of as-built samples. Surface distribution of residual stresses and the effect of scanning strategy were systematically investigated for SLM-produced AlSi10Mg samples. Microstructural morphology was observed at the interface between sample and building platform and was linked to the surface distribution of residual stresses. This procedure can help us accurately measure the residual stresses in SLM-produced samples and thus better understand its build-up mechanism during the SLM process.

Influence of deposition parameters on the residual stresses of WC-Wo sputtered thin films

MRS Advances ◽  
2020 ◽  
Vol 5 (23-24) ◽  
pp. 1215-1223
Author(s):  
R.R. Phiri ◽  
O.P. Oladijo ◽  
E.T. Akinlabi
Keyword(s):  
Thin Films ◽  
Residual Stress ◽  
Residual Stresses ◽  
Substrate Surface ◽  
Tribological Performance ◽  
X Ray Diffraction ◽  
X Ray ◽  
Compressive Stresses ◽  
Deposition Parameters ◽  
Cobalt Thin Films

AbstractControl and manipulation of residual stresses in thin films is a key for attaining coatings with high mechanical and tribological performance. It is therefore imperative to have reliable residual stress measurements methods to further understand the dynamics involved. The sin2ψ method of X-ray diffraction was used to investigate the residual stresses on the tungsten carbide cobalt thin films deposited on a mild steel surface to understand the how the deposition parameters influence the generation of residual stresses within the substrate surface. X-ray spectra of the surface revealed an amorphous phase of the thin film therefore the stress measured was of the substrate surface and the effects of sputtering parameters on residual stress were analysed. Compressive stresses were identified within all samples studied. The results reveal that as the sputtering parameters are varied, the residual stresses also change. Optimum deposition parameters in terms of residual stresses were suggested.

X-Ray Diffraction Analysis of Steel with Oxidised Surface Layer

2016 ◽  
Vol 368 ◽  
pp. 99-102
Author(s):  
Lukáš Zuzánek ◽  
Ondřej Řidký ◽  
Nikolaj Ganev ◽  
Kamil Kolařík
Keyword(s):  
Residual Stress ◽  
Surface Layer ◽  
Residual Stresses ◽  
Diffraction Analysis ◽  
Oxide Surface ◽  
X Ray Diffraction ◽  
X Ray ◽  
Electrolytic Polishing ◽  
Small Depth

The basic principle of the X-ray diffraction analysis is based on the determination of components of residual stresses. They are determined on the basis of the change in the distance between atomic planes. The method is limited by a relatively small depth in which the X-ray beam penetrates into the analysed materials. For determination of residual stresses in the surface layer the X-ray diffraction and electrolytic polishing has to be combined. The article is deals with the determination of residual stress and real material structure of a laser-welded steel sample with an oxide surface layer. This surface layer is created during the rolling and it prevents the material from its corrosion. Before the X-ray diffraction analysis can be performed, this surface layer has to be removed. This surface layer cannot be removed with the help of electrolytic polishing and, therefore, it has to be removed mechanically. This mechanical procedure creates “technological” residual stress in the surface layer. This additional residual stress is removed by the electrolytic polishing in the depth between 20 and 80 μm. Finally, the real structure and residual stresses can be determined by using the X-ray diffraction techniques.

Determination of the Residual Stress Field around Scratches Using Synchrotron X-Rays and Nanoindentation

2010 ◽  
Vol 652 ◽  
pp. 25-30
Author(s):  
M.K. Khan ◽  
Michael E. Fitzpatrick ◽  
L.E. Edwards ◽  
S.V. Hainsworth
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Small Scale ◽  
X Rays ◽  
X Ray Diffraction ◽  
Residual Stress Field ◽  
Fine Grained ◽  
Load Displacement

The residual strain field around the scratches of 125µm depth and 5µm root radius have been measured from the Synchrotron X-ray diffraction. Scratches were produced using different tools in fine-grained aluminium alloy AA 5091. Residual stresses up to +1700 micro-strains were measured at the scratch tip for one tool but remained up to only +1000 micro-strains for the other tool scratch. The load-displacement curves obtained from nanoindentation were used to determine the residual stresses around the scratches. It was found that the load-displacement curves are sensitive to any local residual stress field present and behave according to the type of residual stresses. This combination of nanoindentation and synchrotron X-rays has been proved highly effective for the study of small-scale residual stresses around the features such as scratches.

A Detailed Evaluation of the Effects of Bulk Residual Stress on Fatigue in Aluminum

2014 ◽  
Vol 891-892 ◽  
pp. 1205-1211 ◽  
Author(s):  
Dale L. Ball ◽  
Mark A. James ◽  
Robert J. Bucci ◽  
John D. Watton ◽  
Adrian T. DeWald ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Effective Utilization ◽  
Stress Effects ◽  
The Past ◽  
Property Data ◽  
Design Cycle ◽  
Detailed Evaluation ◽  
The Impact

The fully effective utilization of large aluminum forgings in aerospace structures has been hampered in the past by inadequate understanding of, and sometimes inaccurate representation of, bulk residual stresses and their impact on both design mechanical properties and structural performance. In recent years, significant advances in both computational and experimental methods have led to vastly improved characterization of residual stresses. As a result, new design approaches which require the extraction of residual stress effects from material property data and the formal inclusion of residual stresses in the design analysis, have been enabled. In particular, the impact of residual stresses on durability and damage tolerance can now be assessed, and more importantly, accounted for at the beginning of the design cycle.

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