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.

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.

Measurement of Bending Residual Stress on a Hull Section of a Submarine

2012 ◽  
Author(s):  
Xavier Ficquet ◽  
Ashley Bowman ◽  
Devkumar Goudar ◽  
Manuel Körner ◽  
Ed J. Kingston
Keyword(s):  
Residual Stress ◽  
Hydrostatic Pressure ◽  
Residual Stresses ◽  
Measurement Techniques ◽  
Hole Drilling ◽  
Deep Hole ◽  
Residual Stress Field ◽  
Sheet Bending ◽  
Bending Process ◽  
Submarine Hull

Explicit understanding of the residual stress field of primary submarine pressure hull induced during fabrication will improve the fidelity of numerical analysis and experimentation. Hence, supporting operational envelope and design life extension initiatives. The fatigue lifetime of a submarine hull depends on the loads generated by hull contraction under the effect of hydrostatic pressure and the residual stresses existing in the absence of external loading. The use of numerical simulation allows a straightforward calculation of the stresses induced by the hydrostatic pressure. The effect of residual stress could be determined using the current failure assessment procedures, like BS7910 and R6. However it is more intricate to determine the residual stresses resulting from the sheet bending process combined with the sheet assembly using a multipass welding process. There are several measurement techniques available to measure residual stresses. They are often classified by their level of destructiveness and their penetration.In order to compare the different measurement techniques an elastic-plastic bent beam sample has been chosen as it is very comparable to the residual stress field induced during the sheet bending process used in the submarine structure. Four bent beams have been measured using five different techniques: Incremental centre hole drilling, ring core, neutron diffraction, slitting and deep hole drilling technique. The results from measurement techniques show an excellent agreement when compared with the FEA. In order to measure a full scale Rubis class submarine hull a limited number of techniques can be used, as the technique needs to be portable. The Deep Hole Drilling (DHD) technique was chosen because the neutron diffraction would require extracting a small test sample of about 400mm × 400mm, hence redistributing the residual stresses that were intended to be measured. Six measurements were carried out at different angular positions to detect variability in manufacture on a Rubis class submarine and a probabilistic calculation was done using all six DHD measurements. The Rubis class measurement results are also compared with two other submarine types, found in the literature. Understanding the three-dimensional behaviour of residual stress in this type of structure provides a valuable resource to the numerical modelling community. The results can also support fatigue and fracture experimental work and may help increasing the operating life of 28 year old French nuclear submarine.

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.

Measurement of Residual Stresses in a Type 316H Stainless Steel Offset Repair in a Pipe Girth Weld

2005 ◽  
Vol 128 (3) ◽  
pp. 420-426 ◽  
Author(s):  
S. Hossain ◽  
C. E. Truman ◽  
D. J. Smith ◽  
P. J. Bouchard
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Pipe Wall ◽  
Three Dimensional ◽  
Hole Drilling ◽  
Element Analysis ◽  
Steel Pipes ◽  
Stress Components ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

This paper presents measurements of the in-plane residual stress components through the wall of a 218mm long, 26mm deep repair weld, offset by 7mm from the centerline of a girth weld joining two type 316H stainless steel pipes approximately 37mm thick. The measurements were obtained using the deep hole drilling technique. Two locations were examined: (i) mid-length of the repair weld and (ii) the stop-end of the repair. Both measurements were taken along the girth weld centerline. The distributions and magnitudes of the measured longitudinal and transverse stress components at the two locations were very similar over the outer half of the pipe wall. Over the inner half of the pipe wall both components of stress were found to be significantly more compressive at the stop-end of the repair than at mid-length. In general, the transverse residual stresses were found to be lower than the longitudinal residual stresses at both locations. The measured stress profiles are compared with predicted residual stresses from a three-dimensional finite element analysis.

Assessment of non-uniform residual stress field of the thermal sprayed stainless steel coatings on aluminium substrates by the integral hole drilling method

2020 ◽  
pp. 095440622091771
Author(s):  
Harouche Mohamed Karim ◽  
Hattali Lamine ◽  
Mesrati Nadir
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Stress Field ◽  
Residual Stresses ◽  
Bond Coat ◽  
High Pressures ◽  
Hole Drilling ◽  
Arc Spraying ◽  
Residual Stress Field ◽  
Stainless Steel Coatings

Thermal spray is one of the most used techniques to produce coatings on structural materials. Such coatings are used as protection against high temperatures, corrosion, erosion and wear. The combined action of high pressures, temperatures and spraying conditions give rise to non-uniform residual stresses. The latter plays an important role in coating design and process parameters optimization. The present work highlights the influence of coatings thickness on the evolution of residual stresses in layered materials. Therefore, thick stainless steel coatings (ASTM 301) of different thicknesses are manufactured by wire arc spraying on aluminium alloy substrates (ASTM 2017A). For a better bond strength, a Ni–Al bond coat is first deposited. Furthermore, a numerically supported hole drilling strain gage method for residual stress field evaluation is proposed. Required calibration coefficients, for the strain–stress transformation formalism based on the integral method, are computed through finite element calculations using Abaqus software. The results indicate that the maximum residual stresses, for all thicknesses, are tensile and range from 140 to 275 MPa. The bond coat does not seem to affect the stress field. Also, it was found that the mean equivalent Von-Mises stress decreases with increasing coating thickness; hence reducing the interfacial adhesion energy of the sprayed materials.

Analysis of Welded Joint Under Residual Stresses

2014 ◽  
Author(s):  
H. P. Jawale ◽  
Rahul Singh
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joint ◽  
Weld Zone ◽  
Welding Process ◽  
Fatigue Behaviour ◽  
Hole Drilling ◽  
Building Structures ◽  
Residual Stress Field ◽  
Stress Relieving

Welded joint is most commonly used for building structures and machine components. Welding process involves heating followed by uneven cooling causing residual stress field. In conjunction with stresses due to external loads, in-service behaviour is affected due to residual stress in welded components. It induces defects, also alters crack initiation life, fatigue behaviour, breaking strength, corrosion resistance and increases the susceptibility of structure to failure by fracture. The residual stress is function of cooling rate and the size of weld. The role of residual stress associated with welding is therefore very important while designing mechanical parts. Conventional methods like heat treatment and shot-peening techniques becomes difficult to be applied for reduction of residual stress in general purpose applications. The work presented in this paper describes the measurement of residual stress using stress relieving method, based on hole-drilling technique. Subsequently, residual stresses are relived and measured using strain rosette near the weld zone. These strains value is converted in to stress value. Residual stress is quantified with respect to yield strength, making it possible to be considered for safe designing of weld components.

Residual Stress Prediction and Relaxation in Welded Tubular Joints under Constant Cyclic Loading

2006 ◽  
Vol 524-525 ◽  
pp. 323-330 ◽  
Author(s):  
Zuheir Barsoum
Keyword(s):  
Thermal Analysis ◽  
Residual Stress ◽  
Residual Stresses ◽  
Fatigue Testing ◽  
Three Dimensional ◽  
Hole Drilling ◽  
Moving Heat Source ◽  
Tubular Joints ◽  
Stress Prediction ◽  
Tubular Joint

In this paper three-dimensional welding simulations were carried out in FE software ANSYS in order to predict transient temperatures and the residual stresses in a three pass welded tubular joints. The thermal analysis and the moving heat source were verified with temperature measurements and the computed residual stresses were verified with hole drilling measurements. Then residual stress relaxation analyses were carried out on the tubular structure, with similar load cases as in earlier fatigue testing on the same tubular joint structures.

Study on Residual-Stress Redistributions During the Process of Manufacture of a Vessel Penetration Set-On Joint

2009 ◽  
Author(s):  
Nobuyoshi Yanagida ◽  
Kazuo Ogawa ◽  
Koichi Saito ◽  
Ed Kingston
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Alloy Steel ◽  
Steel Plate ◽  
Three Dimensional ◽  
Hole Drilling ◽  
Low Alloy Steel ◽  
Butt Weld ◽  
Control Rod ◽  
Inner Surface

The stress-redistribution phenomenon in a vessel penetration set-on joint due to post-weld heat treatment (PWHT) was studied using finite element (FE) analyses and mocked-up experiments. The mocked-up consisted of a nickel-based alloy (NCF600) tube welded onto an alloy-82 cladded, low-alloy steel plate (SQV2A) using an alloy-182 butt weld. The angle of the tube to the plate surface was 45 degrees, simulating a side hill, a control rod drive (CRD), and a stub-tube nozzle attachment used in boiling-water reactor (BWR) plants. PWHT at a temperature of 625 °C was conducted after welding and then the inner surface of the tube was machined. Three-dimensional FE modeling was performed to simulate the cladding, the butt weld, the PWHT, and the inner-surface machining of the tube. Thermal elasto-plastic and thermal elasto-plastic creep analyses were conducted to simulate the process of residual-stress build up and its redistribution by PWHT. To validate the FE analysis, the residual stresses in the mocked-up specimen were experimentally measured using the deep-hole-drilling (DHD) and sectioning methods. The analytical and experimental results revealed that residual-stress redistributions in the mocked-up specimen were different in circumferential positions. High-residual stresses in the low-alloy steel plate were particularly mitigated during the PWHT. The stress relief in the low-alloy steel plate primarily controlled the global stress balance between the cladding, the weld metal, and the stub tube.

Finite Element Modeling of GMAW Process: Evolution and Formation of Residual Stresses Upon Cooling

2004 ◽  
Author(s):  
Mohammad S. Davoud ◽  
Xiaomin Deng
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Arc Welding ◽  
Three Dimensional ◽  
Residual Stress Field ◽  
Full Field ◽  
Elastic And Plastic Deformations ◽  
2D And 3D ◽  
Welding Processes ◽  
Field View

Fusion arc welding processes often generate substantial residual stresses, which may alter the performance of welded structures. Residual stresses are the results of incompatible elastic and plastic deformations in a body. Destructive techniques are generally used to experimentally determine residual stresses. Employment of these methods would not often be possible or practical in industry. In this study, three-dimensional (3D) and two-dimensional (2D) finite element simulations and experimental work have been performed to analyze the thermomechanical problem of GMAW and to obtain a full-field view of the residual stress field. One of the purposes of this study is to examine the formation of residual stresses upon cooling of a weldment. Comparisons of the results of 2D and 3D finite element models reveal many three-dimensional features in the thermomechanical problem of GMAW. The magnitude of longitudinal residual stresses obtained from the 2D model, however, compares well with the results obtained from the 3D model.

Improvement of Residual Stress Determination by Deep Hole Drilling Considering Plastic Deformation

2012 ◽  
Author(s):  
Masahito Mochizuki ◽  
Houichi Kitano ◽  
Shigetaka Okano
Keyword(s):  
Residual Stresses ◽  
High Accuracy ◽  
Fe Analysis ◽  
Stress Fields ◽  
Hole Drilling ◽  
Accuracy Evaluation ◽  
Deep Hole ◽  
Stress Determination ◽  
Deep Hole Drilling ◽  
Drilling Technique

The deep hole drilling technique (DHD) has received much attention in recent years as a method for measuring through-thickness residual stresses. However, the accuracy of the measurements of residual stresses by the DHD technique is affected by the deformation produced in the DHD process. In this study, the effects of the deformation are investigated in detail by FE analysis. Then, a new procedure for high accuracy evaluation of residual stresses by the DHD technique is discussed. In addition, the procedure are applied to the evaluation of some inner stress fields.

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