An Analytical Method for Estimating Welding-Induced Plastic Zone Size for Residual Stress Profile Development

Author(s):  
Xianjun Pei ◽  
Shaopin Song ◽  
Pingsha Dong

As demonstrated in a recent comprehensive study on construction of full-field residual stress profiles for fitness-for-service assessment of pressure vessel and piping components, a reasonable estimate of welding-induced plastic zone size is necessary for introducing a shell theory based solution form (Song et al, 2015 [1–2]). This paper presents an analytical method for estimating plastic zone size by first solving an equivalent one dimensional heat transfer problem in which weld zone is represented by a line segment with initial temperature at melting. Thermoplasticity conditions are then imposed by assuming elastic perfectly plastic behaviors. Finally, an analytical expression is obtained to relate plastic zone boundary to maximum temperature field distribution experienced by material points within the whole domain over the entire heating and cooling history. The solution can be further expressed by a rather simple form with the identification of a characteristic length parameter that signifies inflection point of temperature distribution. So estimated plastic zone sizes for various welded joint types have been compared with finite element residual stress analysis results in which sequentially coupled welding heat transfer and thermo-mechanical analysis procedures are used. A good agreement has been achieved for all cases analyzed. Compared with conventional finite element residual stress analysis procedures, this method offers significant simplicity and efficiency, while being reasonably accurate, particularly for applications in residual stress profile estimation and in evaluation of welding induced distortions in complex structures.

2021 ◽  
Author(s):  
Sachin Bhardwaj ◽  
R. M. Chandima Ratnayake

Abstract Welding is a highly nonlinear temperature distribution process, where the presence of high-temperature gradients leads to the development of significantly high residual stress levels, up to and/or beyond the material yield strength magnitude and localized plastic deformation. To achieve the desired dimensional accuracy, determination of plastic zone size, shape, and location is critically important in reducing or controlling final distortions, decreasing the residual stress according to length scale, and defining the optimum sequence of the welding process. The plastic zone caused by welding has been found to be directly proportional to linear heat input, defined in (J/mm). The use of actual linear heat input in the estimation of welding-induced residual stress in finite element models often results in an overestimation of heat transferred to the fusion zone of the metal. This manuscript highlights the importance of estimating plastic zone, developed during thermal processes like welding, and its role in mitigating final distortion by using a 3-bar model for the determination of final residual stresses. In the second part, previously developed analytical linear heat input solution for 2D residual stress models is discussed and further demonstrated using examples from open literature. Lastly, a sequentially uncoupled thermal and thermo-mechanical finite element analysis (FEA) is performed, using a generalized plane strain element, and concluded by validation of the numerically developed plastic zone size with analytically developed solutions.


Author(s):  
Sai Kosaraju ◽  
Xin Zhao

Abstract A two-dimensional finite element model is developed to simulate the interaction between metal samples and laser-induced shock waves. Multiple laser impacts are applied at each location to increase plastically affected depth and compressive stress. The in-depth and surface residual stress profiles are analyzed at various repetition rates and spot sizes. It is found that the residual stress is not sensitive to repetition rate until it reaches a very high level. At extremely high repetition rate (100 MHz), the delay between two shock waves is even shorter than their duration, and there will be shock wave superposition. It is revealed that the interaction of metal with shock wave is significantly different, leading to a different residual stress profile. Stronger residual stress with deeper distribution will be obtained comparing with lower repetition rate cases. The effect of repetition rate at different spot sizes is also studied. It is found that with larger laser spot, the peak compressive residual stress decreases but the distribution is deeper at extremely high repetition rates.


Author(s):  
S. Anurag ◽  
Y. B. Guo ◽  
Z. Q. Liu

Residual stress prediction in hard turning has been recognized as one of the most important and challenging tasks. A hybrid finite element predictive model has been developed with the concept of plowed depth to predict residual stress profiles in hard turning. With the thermo-mechanical work material properties, residual stress has been predicted by simulating the dynamic turning process followed by a quasi-static stress relaxation process. The residual stress profiles were predicted for a series of plowed depths potentially encountered in machining. The predicted residual stress profiles agree with the experimental one in general. A transition of residual stress profile has been recovered at the critical plowed depth. In addition, the effects of cutting speed, friction coefficient and inelastic heat coefficient on residual stress profiles have also been studied and explained.


2013 ◽  
Vol 842 ◽  
pp. 455-461
Author(s):  
Yu Sha ◽  
Shi Gang Bai ◽  
Ya Hui Wang

Elastic–plastic finite element analyses have been performed to study the compressive stress effect on fatigue crack growth under applied tension–compression loading. The near crack tip stress, crack tip opening displacement and crack tip plastic zone size were obtained for a kinematic hardening material. The results have shown that the near crack tip local stress, displacement and reverse plastic zone size are controlled by the maximum stress intensity factors Kmax and the applied compressive stress σmaxcom under tension–compression. Based on the finite element analysis results, a fatigue crack propagation model using Kmax and σmaxcom as a parameters under tension–compression loading has been developed.The models under tension–compression loading agreed well with experimental observations.


2015 ◽  
Vol 812 ◽  
pp. 321-326 ◽  
Author(s):  
A. Filep ◽  
Márton Benke ◽  
Valéria Mertinger ◽  
Gábor Buza

Technological residual stresses have great importance in the manufacturing processes and the lifetime of components. The residual stresses formed by quenching can be very diverse because of its multiple sources. Alternative quenching processes such as laser hardening have a great potential for different applications. The direction of heat transfer during laser hardening is the opposite compared to conventional quenching. This further increases the complexity of the developed stress state. The residual stress profile and the microstructure formed by laser hardening treatment are investigated in the present manuscript.


2003 ◽  
Vol 125 (3) ◽  
pp. 342-346 ◽  
Author(s):  
Amer Hameed ◽  
R. D. Brown ◽  
J. G. Hetherington

A multi-linear kinematic, two dimensional finite element model incorporating Bauschinger effect, developed using ANSYS commercial software is used to determine the effect of machining both at the bore and at the outside diameter, on the depth of yield, maximum firing pressure and final residual stress field present in an autofrettaged gun tube. The model, which is in good agreement with experimental findings, clearly shows that the reduction in maximum compressive circumferential stress is more sensitive to internal machining than to external machining; the depth of yield remains stable and there is no movement of the elastic-plastic interface, relative to its location before material removal. If the internal machining removes material in which reverse yield has occurred, the maximum firing pressure is not affected. The finite element analysis supported by experimental evidence thus leads to an optimization technique for gun tube design.


Author(s):  
Ankitkumar P. Dhorajiya ◽  
Mohammed S. Mayeed ◽  
Gregory W. Auner ◽  
Ronald J. Baird ◽  
Golam M. Newaz ◽  
...  

Detailed analysis of residual stress profile due to laser micro-joining of two dissimilar biocompatible materials, polyimide (PI) and titanium (Ti), is vital for the long-term application of bio-implants. In this work, a comprehensive three dimensional (3D) transient model for sequentially coupled thermo-mechanical analysis of transmission laser micro-joining of two dissimilar materials has been developed by using the finite element (FE) code ABAQUS, along with a moving Gaussian laser heat source. The laser beam (wavelength of 1100 nm and diameter of 0.2 mm), moving at an optimized velocity, passes through the transparent PI, gets absorbed by the absorbing Ti, and eventually melts the PI to form the bond. The laser bonded joint area is 6.5 mm long by 0.3 mm wide. First the transient heat transfer analysis is performed and the nodal temperature profile has been achieved, and then used as an input for the residual stress analysis. Non-uniform mixed meshes have been used and optimized to formulate the 3D FE model and ensure very refined meshing around the bond area. Heat resistance between the two materials has been modeled by using the thermal surface interaction technique, and melting and solidification issues have been approximated in the residual stress analysis by using the appropriate material properties at corresponding temperature. First the model has been used to observe a good bonding condition with the laser parameters like laser traveling speed, power, and beam diameter (burnout temperature of PI > maximum temperature of PI achieved during heating > melting temperature of PI) and a good combination has been found to be 100 mm/min, 3.14 W and 0.2 mm respectively. Using this combination of parameters in heating, the residual stress profile of the laser-micro-joint has been calculated using FE model after cooling the system down to room temperature of 27 °C and analyzed in detail by plotting the stress profiles on the Ti and PI surfaces. Typically the residual stress profiles on the PI surface show low value in the middle, increase to higher values at about 160 μm from the centerline of the laser travel symmetrically at both sides, and to the contrary, on Ti surface show higher values near the centerline of traveling laser beam. The residual stresses have slowly dropped away on both the surfaces as the distance from the bond region increased further. Maximum residual stresses on both the Ti and PI surfaces are at the end of the laser travel, and are in the orders of the yield stresses of respective materials.


2021 ◽  
Author(s):  
Felipe Torres ◽  
Ruben Fernandez

Abstract The understanding of residual stress is of critical importance in the cold spray and thermal spray processes. It has a direct effect on the integrity of the coating related to the adhesion strength, fatigue life, and can lead to undesired effects such as the delamination of the coating. In cold spray, several investigations have evaluated the impact of the residual stress on the coatings, and it is generally accepted that cold spray coatings follow a similar profile to those obtained in the shot peening process. Although the measurement of residual stresses gives fundamental insight into the process, the estimation of such stresses considering the deposition of each layer by numerical methods has not been extensively studied. This work proposes a method for analyzing the evolution of residual stress on a cold spray coating, both on the coating and the substrate, as a function of the deposited layers, using Finite Element Analysis (FEA). The evolution of the residual stress profile with the coating thickness was obtained along the transverse direction. The results were compared to experimental and numerical data from previous studies. The influence of the deposition of each layer on the residual stress profile has been discussed.


Author(s):  
Pingsha Dong ◽  
Shaopin Song ◽  
Jinmiao Zhang

This paper aims to provide a detailed assessment of some of the existing residual stress profiles prescribed in widely used fitness-for-service assessment codes and standards, such as BS 7910 Appendix Q, by taking advantage of some comprehensive residual studies that become available recently. After presenting a case study on which residual stress measurements are available for validating finite element based residual stress solution procedure, residual stress profiles stipulated in BS 7910 for girth welds are evaluated in the context of a series of parametric finite element results and a shell theory based full-field residual stress estimation scheme. As a result, a number of areas for improvement in residual stress profile development are identified, including some specific considerations on how to attain some of these improvements.


Author(s):  
Ankitkumar P. Dhorajiya ◽  
Mohammed S. Mayeed ◽  
Gregory W. Auner ◽  
Ronald J. Baird ◽  
Golam M. Newaz ◽  
...  

Detailed analysis of a residual stress profile due to laser microjoining of two dissimilar biocompatible materials, polyimide (PI) and titanium (Ti), is vital for the long-term application of bio-implants. In this work, a comprehensive three-dimensional (3D) transient model for sequentially coupled thermal/mechanical analysis of transmission laser (laser beam with wavelength of 1100 nm and diameter of 0.2 mm) microjoining of two dissimilar materials has been developed by using the finite element code ABAQUS, along with a moving Gaussian laser heat source. First the model has been used to optimize the laser parameters like laser traveling speed and power to obtain good bonding (burnout temperature of PI>maximum temperature of PI achieved during heating>melting temperature of PI) and a good combination has been found to be 100 mm/min and 3.14 W for a joint-length of 6.5 mm as supported by the experiment. The developed computational model has been observed to generate a bonding zone that is similar in width (0.33 mm) to the bond width of the Ti/PI joint observed experimentally by an optical microscope. The maximum temperatures measured at three locations by thermocouples have also been found to be similar to those observed computationally. After these verifications, the residual stress profile of the laser microjoint (100 mm/min and 3.14 W) has been calculated using the developed model with the system cooling down to room temperature. The residual stress profiles on the PI surface have shown low value near the centerline of the laser travel, increased to higher values at about 165 μm from the centerline symmetrically at both sides, and to the contrary, have shown higher values near the centerline on the Ti surface. Maximum residual stresses on both the Ti and PI surfaces are obtained at the end of laser travel, and are in the orders of the yield stresses of the respective materials. It has been explained that the patterned accumulation of residual stresses is due to the thermal expansion and contraction mismatches between the dissimilar materials at the opposite sides of the bond along with the melting and softening of PI during the joining process.


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