Effects of the Vibration Amplitude in Vibratory Stress Relief on the Fatigue Life of Structures

This research aims to investigate the effects of vibration amplitude in vibratory stress relief (VSR) on the fatigue strength of structures with residual stress. Experiments are carried out on specimens with residual stress generated by local heating. Flat specimens made of A36 steel are prepared to be suitable for setting up fatigue bending tests on a vibrating table. Several groups of samples are subjected to VSR at resonant frequencies with different acceleration amplitudes. The results show that VSR has an important influence on the residual stress and fatigue limit of steel specimens. The maximum residual stress in the samples is reduced about 73% when the amplitude of vibration acceleration is 57 m/s2. The VSR method can also improve the fatigue limit by up to 14% for steel samples with residual stress.

Analysis of thermal-force coupling stress field under the temperature of alternating of molecular sieve adsorption tower

The thermal stress of molecular sieve adsorption tower under transient temperature of 40-290°C is the basis for ensuring the safe operation of the adsorption tower. In this paper, based on the transient thermodynamics theory, the finite element model of the full-size adsorption tower is established. The distribution of thermal stress at the key positions of the tower body is analyzed, and the strength of the maximum equivalent stress position is evaluated. The results show that the maximum residual stress is at the corner of the inner wall of the tower opening to take over the import and export, the maximum is 313.34MPa, and the effect force is gradually diffused along the takeover; The thermal stress on the inside and outside of the skirt is greater than the thermal stress on the inside and outside of the head. The corresponding stress linearization results of each assessment path were evaluated and passed. The strength design, life prediction and maintenance of adsorption tower in complex temperature cross-change conditions provide theoretical basis.

Investigation of tungsten/MA956 steel diffusion bonding with an Nb/Ni composite interlayer

Diffusion bonding is an effective method for joining dissimilar materials. In this study, dissimilar metals of MA956 steel and tungsten (W) were diffusion bonded with Ni/Nb composite interlayer. The experiments were carried out at [Formula: see text], 20 MPa for 20 min in vacuum by spark plasma sintering (SPS) technique. The microstructure and mechanical properties of the bonded joints were evaluated. SEM images and the results of elementary composition indicate that no intermetallics formed at Ni/MA956 steel and Nb/W interfaces, but [Formula: see text] and [Formula: see text] formed at the Nb/Ni interface. Compared with the directly bonded joint between W and MA956 steel, the average shear strength of the joint with Nb/Ni composite interlayer significantly increased to 270 MPa. Although the result of joint residual stresses simulation shows that the maximum residual stress was near the W substrate, the joints with composite interlayer in shear experiments fractured at Nb/Ni interface. The hardness changes along joint interfaces indicate the formation of intermetallic compounds and solid solution phases in the diffusion layers.

Study on Residual Stress of Welded Hoop Structure

Residual stress is inevitable during welding, which will greatly affect the reliability of the structure. The purpose of this paper was to study the residual stress of the hoop structure caused by the cooling shrinkage of the weld when the outer cylinder was wrapped and welded under the condition of the existing inner cylinder. In this paper, the “method of killing activating elements” of ANSYS was used to simulate the three-dimensional finite element of the hoop structure. In the case of applying interlayer friction, the welding-forming process and welding circumferential residual stress of the hoop structure were analyzed. The blind hole method was used to test the residual stress distribution of the hoop structure, and the test results were compared with the finite element simulation results to verify the reliability of the simulation calculation method and the reliability of the calculation results. Then, the influence factors of the maximum welding residual stress of the hoop structure were studied. The results show that the maximum residual stress of the outer plate surface of the hoop structure decreases with the increase of the welding energy, the thickness of the laminate, the width of the weld seam, the welding speed, and the radius of the container. Based on the results of numerical simulation, the ternary first-order equations of the maximum residual stress of the hoop structure with respect to the welding speed, the thickness of the laminate, and the width of the weld seam were established. Then, the optimal welding parameters were obtained by optimizing the equations, which provided an important basis for the safe use and optimal design of the welding hoop structure.

HRSG-Pipeline Weld Residual-Stress Measurement to Assess Influence Over Creep-Analysis Results From Italian Code, American Standard

Previous study carried out residual stress characterization for the welds of the high-temperature-section (superheater / reheater) lower headers of the bottom-supported heat-recovery steam generator (HRSG). Modeling the gas-tungsten arc, manual welding process considered only weld-lay for the ASTM A 335-Grade P22 finned-tube angle joint to the cylinder. Present study aims at indirectly assessing findings of previous analysis measuring maximum residual stress on the joint’s exservice material. To achieve that a tee similar to the previous was not available: for both experimental and numerical analyses present study considers a P22 circumferential “V”-groove butt joint on HRSG pipeline section, creep-operated for the same period and temperature as the previous case. In the experimental activity X-ray diffraction method (or alternatively, hole-drilling strain gage one) applies as close as possible to the weld, being residual stress maximum at the fusion boundary. Thermal analysis for the previous case also showed it keeps nearly constant during weld cooling, relaxing most during creep: after 200,000 hours of operation, welding-process simulation predicted a maximum residual stress of 70 MPa; tee-joint creep-analysis found out a maximum equivalent stress of 91 MPa. As for the sample withdrawal, dimensions should be sufficient to avoid any interference with measurement area. The experimental procedures should comply with the European standard EN 15305 on the matter (the American standard ASTM E 837 for the alternate method). Comparison of analysis results for the two cases, confirms tendencies previously found out in creep-behavior, though different equivalent stress contributions. Comparison of predicted and observed residual stress values should allow for validation of numerical models used in both welding process and stress analysis.

Effect of Ageing on Residual Stresses in a Girth Welded Stainless Steel 316 L Pipe

Residual stresses within welded components can redistribute when exposed to high temperatures and large levels of loading. The ageing process for a specimen attempts to replicate the temperature regime experienced during typical service use of the component, redistributing stresses from the as-welded condition to post-ageing. The aim of this investigation was to study the effects of ageing on weld residual stress redistribution and to evaluate the changes in the residual stress profiles before and after the pipe had been aged. In this investigation the through thickness residual stresses within a narrow gap girth TIG welded stainless steel 316L pipe were measured. The ageing of the pipe specimen involved heating to 400°C for 3000 hours. To measure residual stress the incremental Deep-Hole Drilling (iDHD) method was employed; two measurements were taken, once before and after ageing. Analysis of the measured pre and post-ageing residual stresses showed a consistent reduction in the magnitude of approximately 50 MPa, corresponding to the change in the yield stress of the material at room and elevated (400°C) temperatures; the maximum residual stress, of 450 MPa, was measured at 4 mm from the external surface of the pipe.

Effect of Bonding Temperature on Crack Occurrences in Al2O3/SS 430 Joints Using Cu-Based Brazing Alloys

The effect of bonding temperature on crack occurrences in α-Al2O3/SS 430 joints using Cu-based brazing alloys was investigated with emphasis on the microstructural characterization, hardness, and analytical residual stresses of the joints. The brazing was conducted using Cu-7Al-xTi and Cu-7Al-xZr (x = 2.5, 3.5, and 4.5) alloys at 1000 °C and 1080 °C leading to solid–liquid and liquid-state bonding, respectively. Cracks occurred in the joints brazed at 1080 °C irrespective of the alloys, while crack-free joints were obtained at 1000 °C for joints with only Cu-7Al-xZr alloys. Increases in the bonding temperature or utilization of Cu-7Al-xTi alloys led to a formation of brittle Fe-containing intermetallic or Fe-Cr phases in the brazed seams due to the dissolution of Fe from SS 430, which deteriorated the mechanical properties of the brazed seam. Maximum residual stresses of the real brazed joint were obtained by combining the calculated yield strength and measured hardness of the brazed seams. Eventually, when the hardness of the brazed seam was less than 107 Hv, the yield strength was 124 MPa or less and the maximum residual stress generated in the joint corresponded to 624 MPa or less, leading to a crack-free joint.

Response surface approach to minimize the residual stresses in full penetration pulsed TIG weldments of Ti-5Al-2.5Sn alloy

Pulsation of current in tungsten inert gas (TIG) welding is employed to obtain good quality weldments. Peak current, background current, and welding speed in TIG welding are important parameters and their effects on the induced residual stresses are studied using Box–Behnken design methodology. The location of maximum residual stress was found to be close to the weld centerline. Longitudinal and transverse residual stresses at this location were found to be dependent on the pulsed TIG welding input parameters. However, using design of experiment approach, welding speed was found to have the most dominant influence on the stress values. In order to minimize the residual stresses, a reduction in heat input also led to reduction of weld pool penetration. The results of multiresponse optimization showed that in order to achieve a full penetration weldment, a minimum value of 235 MPa for longitudinal and 84 MPa for transverse residual stress will be attained. A weldment with these features can be obtained by using a high value of peak current and a high value of welding speed.

Residual Stress Assessment for Pressure Vessel Subject to Thermal Shock

API 579-1/ASME FFS-1 Part 9 provides assessment procedures for evaluating crack-like flaws in components to determine if it is fit for continued service. Although residual stress distribution is required as an input to perform a fatigue life assessment, no procedure or guideline is available for evaluating this crack driving force resulting from thermal shocks. Through a systematic analysis, a conservative residual stress distribution can be obtained for pressure vessels subject to thermal shocks. For the two thick-walled vessels considered, the maximum residual stress occurs when the vessel is half filled with water. The conservative residual stress provides the needed input when using API 579-1/ASME FFS-1 for evaluating crack-like flaws in components. Dependence of the residual stress on film coefficient, temperature difference between water and metal surface, and water level inside the vessel is also presented so that refinement can be made on life assessment when additional field data becomes available.