Behavior of Compressive Residual Stresses in High Strength Steel Welds Induced by High Frequency Mechanical Impact Treatment

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Mansoor Khurshid ◽  
Zuheir Barsoum ◽  
Gary Marquis
Keyword(s):  
Residual Stresses ◽  
Welded Joints ◽  
High Frequency ◽  
Fatigue Testing ◽  
Research Work ◽  
High Strength ◽  
Fatigue Loading ◽  
Element Analysis ◽  
Mechanical Impact ◽  
Compressive Residual Stresses

Residual stress state plays an important role in the fatigue life of welded structures. The effect can be beneficial or detrimental, depending on the nature of residual stresses. High frequency mechanical impact (HFMI) treatment is a postweld fatigue improvement technique for welded joints. In this research work the behavior of compressive residual stresses induced in welded joints in high strength steels (HSS) by HFMI treatment has been investigated. Longitudinal nonload carrying attachments in HSS are tested with constant amplitude (CA) and variable amplitude (VA) fatigue loading. Stress concentration factors have been calculated using finite element analysis (FEA). Residual stresses have been measured at different cycles during fatigue testing using X-ray diffraction technique. It is observed that the induced residual stresses are quite stable with some relaxation in CA and VA loading. The overloads in VA loading seem to be more detrimental. Relaxation of residual stresses is more obvious in VA tests.

Behavior of Compressive Residual Stresses in High Strength Steel Welds Induced by High Frequency Mechanical Impact Treatment

2013 ◽  
Author(s):  
Mansoor Khurshid ◽  
Zuheir Barsoum ◽  
Gary Marquis
Keyword(s):  
Residual Stresses ◽  
Welded Joints ◽  
High Frequency ◽  
Fatigue Testing ◽  
Research Work ◽  
High Strength Steels ◽  
High Strength ◽  
Element Analysis ◽  
Mechanical Impact ◽  
Compressive Residual Stresses

Residual stress state plays an important role in the fatigue life of welded structures. They can be beneficial or detrimental, depending on the nature of residual stresses. High frequency mechanical impact (HFMI) treatment is a post-weld fatigue improvement technique for welded joints. In this research work the behavior of compressive residual stresses induced in welded joints in high strength steels (HSS) by HFMI treatment has been investigated. Longitudinal non load carrying attachments in HSS are tested with constant amplitude (CA) and variable amplitude (VA) loading. Stress concentration factors have been calculated using Finite Element Analysis (FEA). Residual stresses have been measured at different cycles during fatigue testing using X-ray diffraction technique. It is observed that the induced residual stresses are quite stable with some relaxation in CA and VA loading. The overloads in VA loading seem to be more detrimental. Relaxation of residual stresses is more obvious in VA tests.

scholarly journals New And Existing Bridge Constructions - Increase of Fatigue Strength of Welded Joints by High Frequency Mechanical Impact Treatment

2013 ◽  
Vol 2 (1) ◽  
pp. 88-101
Author(s):  
Thomas Ummenhofer ◽  
Philipp Weidner ◽  
Tim Zinke
Keyword(s):  
Fatigue Strength ◽  
Welded Joints ◽  
High Frequency ◽  
Research Work ◽  
Steel Structures ◽  
Current Status ◽  
Small Scale ◽  
Welded Steel ◽  
Mechanical Impact ◽  
Existing Structures

Abstract Numerous studies at KIT prove that high frequency mechanical impact (HFMI) treatment is an efficient method for increasing the fatigue strength of welded steel structures. Within different research projects it was found that HFMI-methods can be used successfully for new and existing structures in order to extend the fatigue life. This paper gives an overview of the current status of existing steel bridges in Germany regarding aspects like bridge age distributions and traffic loads. Based on that overview welded joints susceptible to fatigue failure are identified. Using component-like small scale specimens, HFMI-methods were investigated within the objective of implementing an effective application for new and existing structures. Applying the fatigue test data observed, existing design proposals are evaluated and design recommendations for HFMI-treated joints are given. As a result of the research work, a transfer into practice has been realized and different applications are illustrated using the example of bridge constructions made of steel.

Finite Element Analysis of Residual Stresses on Butt Welded Joints

2006 ◽  
Author(s):  
Enrico Armentani ◽  
Renato Esposito ◽  
Raffaele Sepe
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Fusion Zone ◽  
Welded Joints ◽  
High Strength Steels ◽  
High Strength ◽  
Heat Of Fusion ◽  
Temperature Dependent ◽  
Element Analysis ◽  
Welding Processes

Localized heating during welding, followed by rapid cooling, usually generates residual stresses in the weld and in the base metal. Residual stresses in welding processes give significant problems in the accurate manufacture of structures because those stresses heavily induce the formation of cracks in the fusion zone in high strength steels. Therefore, estimating the magnitude and distribution of welding residual stresses and characterizing the effects of certain welding conditions on the residual stresses are deemed necessary. In this work, residual stresses and distortions on butt welded joints are numerically evaluated by means of finite element method. The FE analysis allows to highlight and evaluate the stress field and his gradient around the fusion zone of welded joints, higher than any other located in the surrounding area. Temperature-dependent material properties, welding velocity, external mechanism constraints, technique of ‘element birth and death’ and latent heat of fusion are also taken into account. Some numerical results are compared with experimental data showing a very good correlation.

Benefits of Ultrasonic Peening Treatment in Fatigue Improvement of Welded Elements

2012 ◽  
Author(s):  
Jacob Kleiman ◽  
Yuri Kudryavtsev ◽  
Alexander Lugovskoy
Keyword(s):  
Mechanical Properties ◽  
Fatigue Strength ◽  
Residual Stresses ◽  
Fatigue Testing ◽  
High Strength Steels ◽  
High Strength ◽  
Fatigue Loading ◽  
Surface Layers ◽  
Ultrasonic Peening ◽  
Weld Toe

The Ultrasonic Peening (UP) is one of new and promising processes for fatigue life improvement of welded elements and structures. During the different stages of its development the UP process was also known as ultrasonic treatment (UT), ultrasonic impact treatment (UIT), ultrasonic impact peening (UIP). The beneficial effect of UP is achieved mainly by relieving of harmful tensile residual stresses and introducing of compressive residual stresses into surface layers of material, decreasing of stress concentration in weld toe zones and enhancement of mechanical properties of the surface layers of the material. The results of fatigue testing of welded elements made of regular and high strength steels in as-welded condition and after application of UP will be presented. The yield strength of considered materials varied from 250–350 MPa to 700–1000 MPa. It is shown that UP is the most effective and economic technique for increasing of fatigue strength of welded elements in materials of different strength. These results also show a strong tendency of increased fatigue strength of welded elements after application of UP with the increase in mechanical properties of the material used. It allows using to a greater degree the advantages of the HSS in welded elements, subjected to fatigue loading.

Effects of Residual Stresses on the Fatigue Performance of Welded Steels with Longitudinal Stiffeners

2013 ◽  
Vol 768-769 ◽  
pp. 636-643 ◽  
Author(s):  
Jonas Hensel ◽  
Thomas Nitschke-Pagel ◽  
Klaus Dilger ◽  
Steffen Schönborn
Keyword(s):  
Fatigue Strength ◽  
Residual Stresses ◽  
Stress Ratio ◽  
Fatigue Testing ◽  
High Strength ◽  
Fatigue Loading ◽  
X Ray ◽  
Initial Residual Stress ◽  
Stress Relieving ◽  
Longitudinal Stiffeners

Residual stresses may affect the behavior of welded steels under fatigue loading. However, for design of welded structures the height and distribution of residual stresses from welding are often not known so that tensile residual stresses in the order of the yield strength are conservatively assumed. Here presented results focus on the influence of residual stresses on the fatigue strength of longitudinal stiffeners made from a mild steel S355NL and a high strength steel S960QL. The initial residual stress conditions were measured using X-ray and neutron diffraction. In order to characterize the influence of residual stresses on the fatigue strength, specimens were tested in the as-welded condition and after a stress relieving heat treatment. The fatigue testing was conducted under alternating constant amplitude loading with a stress ratio of R=-1.

Surface Modification Analysis after Shot Peening of AA 7075 in Different States

2013 ◽  
Vol 768-769 ◽  
pp. 519-525 ◽  
Author(s):  
Sebastjan Žagar ◽  
Janez Grum
Keyword(s):  
Residual Stress ◽  
Surface Layer ◽  
Residual Stresses ◽  
Aluminium Alloy ◽  
Shot Peening ◽  
Fatigue Testing ◽  
Stress Profile ◽  
Treatment Conditions ◽  
Stress Profiles ◽  
Compressive Residual Stresses

The paper deals with the effect of different shot peening (SP) treatment conditions on the ENAW 7075-T651 aluminium alloy. Suitable residual stress profile increases the applicability and life cycle of mechanical parts, treated by shot peening. The objective of the research was to establish the optimal parameters of the shot peening treatment of the aluminium alloy in different precipitation hardened states with regard to residual stress profiles in dynamic loading. Main deformations and main residual stresses were calculated on the basis of electrical resistance. The resulting residual stress profiles reveal that stresses throughout the thin surface layer of all shot peened specimens are of compressive nature. The differences can be observed in the depth of shot peening and the profile of compressive residual stresses. Under all treatment conditions, the obtained maximum value of compressive residual stress ranges between -200 MPa and -300 MPa at a depth between 250 μm and 300 μm. Comparison of different temperature-hardened aluminium alloys shows that changes in the Almen intensity values have greater effect than coverage in the depth and profile of compressive residual stresses. Positive stress ratio of R=0.1 was selected. Wöhler curves were determined in the areas of maximum bending loads between 30 - 65 % of material's tensile strength, measured at thinner cross-sections of individual specimens. The results of material fatigue testing differ from the level of shot peening on the surface layer.

Simplified FEA Models in the Analysis of the Redistribution of Beneficial Compressive Stresses in Welds During Cyclic Loading

2018 ◽  
Author(s):  
B. L. Josefson ◽  
J. Alm ◽  
J. M. J. McDill
Keyword(s):  
Cyclic Loading ◽  
Residual Stresses ◽  
Compressive Stress ◽  
Welding Process ◽  
Plastic Behavior ◽  
Element Analysis ◽  
Compressive Stresses ◽  
Static Contact ◽  
Weld Toe ◽  
Compressive Residual Stresses

The fatigue life of welded joints can be improved by modifying the weld toe geometry or by inducing beneficial compressive residual stresses in the weld. However, in the second case, the induced compressive residual stresses may relax when the welded joint is subjected to cyclic loading containing high tensile or compressive stress peaks. The stability of induced compressive stresses is investigated for a longitudinal gusset made of a S355 steel. Two methods are considered; either carrying out a high frequency mechanical impact (HFMI) treatment after welding or alternatively using low transformation temperature (LTT) electrodes during welding. The specimen is then subjected to a cyclic loading case with one cycle with a tensile peak (with magnitude reaching the local yield stress level) followed by cycles with constant amplitude. A sequential finite element analysis (FEA) is performed thereby preserving the history of the elasto-plastic behavior. Both the welding process and the HFMI treatment are simulated using simplified approaches, i.e., the welding process is simulated by applying a simplified thermal cycle while the HFMI treatment is simulated by a quasi-static contact analysis. It is shown that using the simplified approaches to modelling both the welding process and HFMI treatment gives results that correlate qualitatively well with the experimental and FEA data available in the literature. Thus, for comparison purposes, simplified models may be sufficient. Both the use of the HFMI treatment and LTT electrodes give approximately the same compressive stress at the weld toe but the extent of the compressive stress zone is deeper for HFMI case. During cyclic loading it is shown that the beneficial effect of both methods will be substantially reduced if the test specimen is subjected to unexpected peak loads. For the chosen load sequence, with the same maximum local stress at the weld toe, the differences in stress curves of the HFMI-treated specimen and that with LTT electrodes remain. While the LTT electrode gives the lowest (compressive) stress right at the well toe, it is shown that the overall effect of the HFMI treatment is more beneficial.

The Effect of Several Finishing Processes on the Fatigue Resistance of Hole Surfaces

1989 ◽  
Vol 111 (1) ◽  
pp. 71-73 ◽  
Author(s):  
M. O. Lai ◽  
A. Y. C. Nee
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Fatigue Resistance ◽  
Radial Direction ◽  
Fatigue Loading ◽  
Steel Plates ◽  
Finishing Processes ◽  
Compressive Residual Stresses

This investigation examines the effects of different finishing processes on the fatigue life of premachined holes in Assab 760 steel plates. The finishing processes studied were reaming, ballizing, and emery polishing. A general decrease in fatigue life with increase in surface roughness is observed for all the processes employed. In comparing the different processes, for a constant surface roughness, polishing is generally found to give the longest fatigue life while ballizing, in spite of the greater compressive residual stresses induced on the surface of the finished hole, the shortest. The surprising phenomenon was found to be attributed to the amount of plastic deformation occurred before fatigue loading. For Assab 760 steel, a prestrain in the radial direction of less than about 2.5 percent appeared to reduce the fatigue resistance of the material.

scholarly journals Low-cycle fatigue behaviour of laser welded high-strength steel DOMEX 700 MC

2018 ◽  
Vol 157 ◽  
pp. 05013 ◽  
Author(s):  
Peter Kopas ◽  
Milan Sága ◽  
František Nový ◽  
Bohuš Leitner
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
High Strength Steel ◽  
Fatigue Testing ◽  
Low Cycle Fatigue ◽  
High Strength ◽  
Fatigue Behaviour ◽  
Total Strain Amplitude ◽  
Cycle Fatigue ◽  
Fatigue Life Analysis

The article presents the results of research on low cycle fatigue strength of laser welded joints vs. non-welded material of high-strength steel DOMEX 700 MC. The tests were performed under load controlled using the total strain amplitude ɛac. The operating principle of the special electro-mechanic fatigue testing equipment with a suitable clamping system was working on 35 Hz frequency. Fatigue life analysis was conducted based on the Manson-Coffin-Basquin equation, which made it possible to determine fatigue parameters. Studies have shown differences in the fatigue life of original specimens and laser welded joints analysed, where laser welded joints showed lower fatigue resistance. In this article a numerical analysis of stresses generated in bending fatigue specimens has been performed employing the commercially available FEM-program ADINA.

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