scholarly journals Intermethod Comparison and Evaluation of Measured Near Surface Residual Stress in Milled Aluminum

2021 ◽  
Author(s):  
C. R. Chighizola ◽  
C. R. D’Elia ◽  
D. Weber ◽  
B. Kirsch ◽  
J. C. Aurich ◽  
...  
Keyword(s):  
Residual Stress ◽  
Material Removal ◽  
Flat Surface ◽  
Cutting Speed ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Near Surface ◽  
X Ray ◽  
Milled Surface

Abstract Background While near surface residual stress (NSRS) from milling is a driver for distortion in aluminum parts there are few studies that directly compare available techniques for NSRS measurement. Objective We report application and assessment of four different techniques for evaluating residual stress versus depth in milled aluminum parts. Methods The four techniques are: hole-drilling, slotting, cos(α) x-ray diffraction (XRD), and sin2(ψ) XRD, all including incremental material removal to produce a stress versus depth profile. The milled aluminum parts are cut from stress-relieved plate, AA7050-T7451, with a range of table and tool speeds used to mill a large flat surface in several samples. NSRS measurements are made at specified locations on each sample. Results Resulting data show that NSRS from three techniques are in general agreement: hole-drilling, slotting, and sin2(ψ) XRD. At shallow depths (< 0.03 mm), sin2(ψ) XRD data have the best repeatability (< 15 MPa), but at larger depths (> 0.04 mm) hole-drilling and slotting have the best repeatability (< 10 MPa). NSRS data from cos(α) XRD differ from data provided by other techniques and the data are less repeatable. NSRS data for different milling parameters show that the depth of NSRS increases with feed per tooth and is unaffected by cutting speed. Conclusion Hole-drilling, slotting, and sin2(ψ) XRD provided comparable results when assessing milling-induced near surface residual stress in aluminum. Combining a simple distortion test, comprising removal of a 1 mm thick wafer at the milled surface, with a companion stress analysis showed that NSRS data from hole-drilling are most consistent with milling-induced distortion.

Measuring the Variation of Residual Stress with Depth: A Validation Exercise for Fine Incremental Hole Drilling

2006 ◽  
Vol 524-525 ◽  
pp. 531-537 ◽  
Author(s):  
A. Tony Fry ◽  
Jerry D. Lord
Keyword(s):  
Residual Stress ◽  
Neutron Diffraction ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Near Surface ◽  
X Ray ◽  
Treatment Processes ◽  
Incremental Hole Drilling ◽  
Significant Interest

Hole drilling along with X-Ray diffraction, is one of the most widely used techniques for measuring residual stress, but the conventional approach is limited in the near surface detail that can be resolved. Because of concerns regarding the levels of induced residual stress that might develop during machining and surface treatment processes, there is significant interest in developing a technique that can obtain near surface residual stress information by the application of fine increment hole drilling. Through a cross comparison with X-ray diffraction and neutron diffraction the procedure of fine incremental drilling has been validated, and the advantages of this technique demonstrated.

Revision and extension of the standard laboratory technique for X-ray diffraction measurement of residual stress gradients

2007 ◽  
Vol 40 (4) ◽  
pp. 675-683 ◽  
Author(s):  
Cristy L. Azanza Ricardo ◽  
Mirco D'Incau ◽  
Paolo Scardi
Keyword(s):  
Residual Stress ◽  
Hole Drilling ◽  
Al Alloy ◽  
Diffraction Measurement ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
X Ray ◽  
Stress Gradients ◽  
Layer Removal ◽  
Removal Technique

A new procedure is proposed to determine sub-surface residual stress gradients by laboratory X-ray diffraction measurements at different depths using a chemical layer-removal technique. The standard correction algorithm for stress relaxation due to layer removal is improved by including corrections for X-ray absorption, and by the addition of constraints imposed by the mechanical equilibrium conditions. Besides correcting the data,i.e.providing more reliable through-thickness residual stress trends, the proposed procedure also provides an elastically compatible and plausible estimate of the residual stress inside the component, well beyond the measured region. The application of the model is illustrated for a set of Al-alloy components shot-peened at different Almen intensities. Results are compared with those given by `blind hole drilling', which is an independent and partly destructive method.

Analysis of Multiaxial Near-Surface Residual Stress Fields by Energy- and Angle-Dispersive X-ray Diffraction: Semi- Versus Nondestructive Techniques

2018 ◽  
Vol 7 (4) ◽  
pp. 20170135
Author(s):  
Matthias Meixner ◽  
Manuela Klaus ◽  
Wolfgang Zinn ◽  
Daniel Apel ◽  
Alexander Liehr ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Fields ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Near Surface ◽  
X Ray ◽  
Nondestructive Techniques

Micro-slotting technique for reliable measurement of sub-surface residual stress in Ti-6Al-4V

2018 ◽  
Vol 53 (6) ◽  
pp. 389-399 ◽  
Author(s):  
Elizabeth Burns ◽  
Joseph Newkirk ◽  
James Castle
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Image Correlation ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Near Surface ◽  
X Ray ◽  
Measurement Volume ◽  
Surface Residual Stresses

Micro-slotting, a relaxation residual stress measurement technique, has recently been shown to be an effective method for measuring local residual stresses in a variety of materials. The micro-slotting method relies on a scanning electron microscope–focused ion beam system for milling and imaging, digital image correlation software to track displacements due to residual stress relaxation after milling, and finite element analysis for displacement–stress correlation and calculation of the original stress state in the imaged region. The high spatial resolution of the micro-slotting method makes it a promising technique for obtaining near-surface residual stress data in Ti-6Al-4V components for input into fatigue life models and crack growth simulations. However, use of the micro-slotting method on this alloy has yet to be evaluated against more established measurement techniques. In this study, spatially resolved sub-surface residual stress measurements were obtained on shot peened and low-stress surface-machined Ti-6Al-4V planar coupons using the micro-slotting method and were compared to measurements obtained using the conventional X-ray diffraction depth profiling technique. The sub-surface measurements were in good agreement for the shot peened sample. Observed differences in the measured near-surface residual stresses on the surface-machined sample were attributed to the larger measurement volume of the X-ray diffraction method, suggesting that the micron-sized measurement volume of the micro-slotting method may be more suitable for capturing shallow stress profiles and steep stress gradients. Prior to performing the micro-slotting measurements, finite element modeled displacements were used to verify the measurement procedure and to address uncertainties in the milled slot geometries. The results of this study demonstrated the validity of the micro-slotting procedure and established the technique as a reliable method for measuring sub-surface residual stresses in Ti-6Al-4V.

Residual Stress Depth Profiling on Ground and on Polished Surfaces of an Al2O3/SiC(w) Composite

1995 ◽  
Vol 39 ◽  
pp. 371-380
Author(s):  
X. Zhu ◽  
P. Predecki ◽  
M. Eatough ◽  
R. Goebner
Keyword(s):  
Residual Stress ◽  
Depth Profiling ◽  
Grazing Incidence ◽  
Inversion Method ◽  
Laplace Method ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Near Surface ◽  
X Ray ◽  
Stress Components

This study uses the asymmetric grazing incidence x-ray diffraction (GIXD) method and related z-profile retrieval techniques to study the near surface residual stress depth proflles on ground and on polished surfaces of hot-pressed Al2O2SiC(w) composite specimen. The z-profiles of stress components σ11, σ22 and σ33 of the Al2O3 matrix were obtained by using the numerical inversion method as well as the inverse Laplace method. Both τ- and z-profiles of residual stresses are presented.

Measurement and Prediction of the Residual Stress Field Generated by Side-Punching

2006 ◽  
Vol 128 (3) ◽  
pp. 451-459 ◽  
Author(s):  
A. H. Mahmoudi ◽  
D. Stefanescu ◽  
S. Hossain ◽  
C. E. Truman ◽  
D. J. Smith ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Measurement Techniques ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
Residual Stress Field ◽  
Surface Residual Stress ◽  
Alloy Plate ◽  
Near Surface

Side-punching is proposed as a method of introducing a well-defined residual stress field into a laboratory-sized test specimen. Such a specimen may subsequently be used to assess the influence of residual stresses on the fracture behavior of materials. Side-punching consists of simultaneously indenting opposite faces of a plate of material with rigid tools, using sufficient force to cause localized yielding over a finite-sized volume of material adjacent to the punching tools. This paper presents experimental measurements, obtained using three independent measurement techniques, of the residual stress field generated in an aluminium alloy plate after side-punching. Incremental center hole drilling is used to determine the near-surface residual stress field, while synchrotron x-ray diffraction and deep hole drilling are used to measure the through-thickness residual stress field along a path linking the two punch center points. Finite element (FE) predictions are also presented and compared to the measurements. There is very good agreement between all three sets of measurements and the FE results, which all show that the through-thickness residual stresses are compressive and attain a maximum value at the center of the plate. The results confirm the potential use of side-punching in residual stress-crack interaction studies.

Effect of Milling Speed and Feed on Surface Residual Stress of 7050-T7451 Aluminum Alloy

2012 ◽  
Vol 499 ◽  
pp. 217-222 ◽  
Author(s):  
C. Li ◽  
Yi Wan ◽  
R.R. Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Speed ◽  
Diffraction Method ◽  
Cutting Condition ◽  
Feed Speed ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Orthogonal Direction ◽  
Machined Surface

The residual stress in the milling of 7050-T7451 aluminum alloy was measured using X-ray diffraction method in which Psi-oscillation, Phi-oscillation and peak fit were adopted. Cutting speed and feed are main variables which were considered in this study. The results show that compressive residual stresses are generated in surface for the down milling generally, which is mainly due to burnishing effect between the tools flank face and the machined surface. In feed and its orthogonal direction, the effect of cutting speed and feed speed on residual stress is similar. Therefore, required residual stress can be achieved by controlling the cutting condition such as cutting speed, feed speed etc.

X-Ray Diffraction Determination of Metallurgical Damage in Turbo Blower Rotor Shafts

1988 ◽  
Vol 142 ◽  
Author(s):  
John F. Porter ◽  
Dan O. Morehouse ◽  
Mike Brauss ◽  
Robert R. Hosbons ◽  
John H. Root ◽  
...  
Keyword(s):  
Residual Stress ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
X Ray ◽  
Turbo Blower ◽  
Diffraction Determination ◽  
Defence Research ◽  
Stress Profiles ◽  
Non Destructive

AbstractStudies have been ongoing at Defence Research Establishment Atlantic on the evaluation of non-destructive techniques for residual stress determination in structures. These techniques have included neutron diffraction, x-ray diffraction and blind-hole drilling. In conjunction with these studies, the applicability of these procedures to aid in metallurgical and failure analysis investigations has been explored. The x-ray diffraction technique was applied to investigate the failure mechanism in several bent turbo blower rotor shafts. All examinations had to be non-destructive in nature as the shafts were considered repairable. It was determined that residual stress profiles existed in the distorted shafts which strongly indicated the presence of martensitic microstuctures. These microstructures are considered unacceptable for these shafts due to the potential for cracking or in-service residual stress relaxation which could lead to future shaft distortion.

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