A non-destructive method to determine the depth-dependence of three-dimensional residual stress states by X-ray diffraction

AbstractCold extruded components are characterized by residual stresses, which originate from the experienced manufacturing process. For industrial applications, reproducibility and homogeneity of the final components are key aspects for an optimized quality control. Although striving to obtain identical deformation and surface conditions, fluctuation in the manufacturing parameters and contact shear conditions during the forming process may lead to variations of the spatial residual stress distribution in the final product. This could lead to a dependency of the residual stress measurement results on the relative axial and circumferential position on the sample. An attempt to examine this problem is made by the employment of design of experiments (DoE) methods. A statistical analysis of the residual stress results generated through X-Ray diffraction is performed. Additionally, the ability of cold extrusion processes to generate uniform stress states is analyzed on specimens of austenitic stainless steel 1.4404 and possible correlations with the pre-deformed condition are statistically examined. Moreover, the influence of the coating, consisting of oxalate and a MoS2 based lubricant, on the X-Ray diffraction measurements of the surface is investigated.

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Non-Destructive Quantitative Phase and Residual Stress Analysis Versus Depth Using Grazing X-Ray Diffraction

Solid State Phenomena - APPLIED CRYSTALLOGRAPHY XX ◽

10.4028/3-908451-40-x.47 ◽

2007 ◽

pp. 47-52

Author(s):

S.J. Skrzypek ◽

M. Goły ◽

Wiktoria Ratuszek ◽

Mieczyslaw Kowalski

Keyword(s):

Residual Stress ◽

Stress Analysis ◽

X Ray Diffraction ◽

X Ray ◽

Quantitative Phase ◽

Residual Stress Analysis ◽

Non Destructive

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

MRS Proceedings ◽

10.1557/proc-142-171 ◽

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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X-Ray Diffraction Measurement of Residual Stresses in Thick, Multi-Pass Steel Weldments

Journal of Pressure Vessel Technology ◽

10.1115/1.3264432 ◽

1985 ◽

Vol 107 (2) ◽

pp. 185-191 ◽

Cited By ~ 4

Author(s):

C. O. Ruud ◽

R. N. Pangborn ◽

P. S. DiMascio ◽

D. J. Snoha

Keyword(s):

Residual Stress ◽

Measurement Accuracy ◽

Stress Measurement ◽

Three Dimensional ◽

Residual Stress Measurement ◽

Stress Fields ◽

Diffraction Measurement ◽

X Ray Diffraction ◽

X Ray ◽

Removal Technique

A unique X-ray diffraction instrument for residual stress measurement has been developed that provides for speed, ease of measurement, accuracy, and economy of surface stress measurement. Application of this instrument with a material removal technique, e.g., electropolishing, has facilitated detailed, high resolution studies of three-dimensional stress fields. This paper describes the instrumentation and techniques applied to conduct the residual stress measurement and presents maps of the residual stress data obtained for the surfaces of a heavy 2 1/4 Cr 1 Mo steel plate weldment.

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Non-destructive Surface Residual Stress Profiling by Multireflection Grazing Incidence X-Ray Diffraction: a 7050 Al Alloy Study

Experimental Mechanics ◽

10.1007/s11340-019-00578-0 ◽

2020 ◽

Vol 60 (4) ◽

pp. 475-480

Author(s):

V. A. N. Righetti ◽

T. M. B. Campos ◽

L. B. Robatto ◽

R. R. Rego ◽

G. P. Thim

Keyword(s):

Residual Stress ◽

Grazing Incidence ◽

Al Alloy ◽

X Ray Diffraction ◽

Surface Residual Stress ◽

X Ray ◽

Non Destructive

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Combined Neutron and X-Ray Diffraction Analysis for the Characterization of a Case Hardened Disc

Materials Science Forum ◽

10.4028/www.scientific.net/msf.652.37 ◽

2010 ◽

Vol 652 ◽

pp. 37-43 ◽

Cited By ~ 9

Author(s):

Jeremy Epp ◽

Thomas Hirsch ◽

Martin Hunkel ◽

Robert C. Wimpory

Keyword(s):

Residual Stress ◽

Neutron Diffraction ◽

Diffraction Analysis ◽

Force Balance ◽

X Ray Diffraction ◽

X Ray ◽

Residual Stress State ◽

Systematic Uncertainties ◽

Combined Use ◽

Stress States

The present work has been executed within the framework of the collaborative research center on Distortion Engineering (SFB 570) in order to evaluate the residual stress state of a disc after carburizing and quenching as well as to validate a simulation procedure. The combined use of X-ray and neutron diffraction analysis provided information about the residual stress states in the whole cross section. However, the stress free lattice spacing d0 for the neutron diffraction experiments is problematic and induces systematic uncertainties in the results and the application of a force balance condition to recalculate d0 might be a solution for improving the reliability of the results. Comparison of experimental results with simulation showed that an overall satisfying agreement is reached but discrepancies are still present.

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Three-dimensional welding residual stresses evaluation based on the eigenstrain methodology via X-ray measurements at the surface

International Journal of Computational Materials Science and Engineering ◽

10.1142/s2047684114500237 ◽

2014 ◽

Vol 03 (04) ◽

pp. 1450023

Author(s):

Masaru Ogawa

Keyword(s):

Neutron Diffraction ◽

Residual Stresses ◽

Three Dimensional ◽

Strain Gauges ◽

X Ray Diffraction ◽

Stress Evaluation ◽

X Ray ◽

Residual Strains ◽

Non Destructive ◽

Evaluation Accuracy

In order to assure structural integrity for operating welded structures, it is necessary to evaluate crack growth rate and crack propagation direction for each observed crack non-destructively. Here, three dimensional (3D) welding residual stresses must be evaluated to predict crack propagation. Today, X-ray diffraction is used and the ultrasonic method has been proposed as non-destructive method to measure residual stresses. However, it is impossible to determine residual stress distributions in the thickness direction. Although residual stresses through a depth of several tens of millimeters can be evaluated non-destructively by neutron diffraction, it cannot be used as an on-site measurement technique. This is because neutron diffraction is only available in special irradiation facilities. Author pays attention to the bead flush method based on the eigenstrain methodology. In this method, 3D welding residual stresses are calculated by an elastic Finite Element Method (FEM) analysis from eigenstrains which are evaluated by an inverse analysis from released strains by strain gauges in the removal of the reinforcement of the weld. Here, the removal of the excess metal can be regarded as non-destructive treatment because toe of weld which may become crack starters can be eliminated. The effectiveness of the method has been proven for welded plates and pipes even with relatively lower bead height. In actual measurements, stress evaluation accuracy becomes poorer because measured values of strain gauges are affected by processing strains on the machined surface. In the previous studies, the author has developed the bead flush method that is free from the influence of the affecting strains by using residual strains on surface by X-ray diffraction. However, stress evaluation accuracy is not good enough because of relatively poor measurement accuracy of X-ray diffraction. In this study, a method to improve the estimation accuracy of residual stresses in this method is formulated, and it is shown numerically that inner welding residual stresses can be estimated accurately from the residual strains measured by X-ray diffraction.

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X-Ray Diffraction Measurements of Residual Stress Induced by Surface Compressing Methods

Materials Science Forum ◽

10.4028/www.scientific.net/msf.729.199 ◽

2012 ◽

Vol 729 ◽

pp. 199-204 ◽

Cited By ~ 1

Author(s):

Dávid Cseh ◽

Valéria Mertinger

Keyword(s):

Residual Stress ◽

Residual Stresses ◽

Surface Region ◽

X Ray Diffraction ◽

X Ray ◽

Hardened Alloy ◽

Compressive Stresses ◽

Machine Parts ◽

Stress States ◽

Operational Behaviour

Residual stresses have a fundamental effect on the operational behaviour and lifetime of industrial products. The fatigue resistance of machine parts can be increased by introducing residual compressive stresses into the surface region. For certain machine parts especially in the vehicle industry the residual stress is strongly demanded by the quality control. For this reason, measuring the stress accurately is becoming increasingly important. The Almen test, which only gives a qualitative result, is widely used in the industry. Shot peening and rolling are methods which are suitable for creating elastic residual stresses. This paper examines the technologies used by Rába Futómű Nyrt. to increase the lifetime by means of residual stress. We performed analysis of the residual stress of samples shot peened the same way but under different heat treatment states. We compared the residual stress values of burnished and hardened shaft joints, and the residual stress states of gear made of hardened alloy, comparing the carbonized ones to ones which were shot peened under small intensity.

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