Evaluate welding residual of 6082-T6 aluminum alloy welded plate by using ultrasonic method

2019 ◽  
Vol 33 (01n03) ◽  
pp. 1940038
Author(s):  
Zhongyin Zhu ◽  
Guoqing Gou ◽  
Zhiyi Zhang ◽  
Chuanping Ma ◽  
Wei Gao
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Ultrasonic Method ◽  
Welding Process ◽  
Diffraction Method ◽  
Element Model ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
Effective Depth ◽  
Good Agreement

The residual stress beneath the surface is crucial to the safety of the structures. Neutron Diffraction and Hole-drilling are the two methods being used to measure the inner residual stress. Longitudinal Critically Refracted (LCR) wave transmission that is propagated parallel to surface also can be used for measuring residual stress, but measurements are within an effective depth and need to be further studied. In this paper, the parameters of K are separately tested in WZ, HAZ and BM zone. The welding process of 6082-T6 aluminum alloy welded joints is simulated in SYSWELD, the finite element model has been verified by the X-ray diffraction method. The residual stress value calculated by SYSWELD and the values obtained from the ultrasonic measurement show a good agreement. It is demonstrated that the residual stress of 6082-T6 aluminum alloy welded plate can be evaluated by using the ultrasonic method.

Residual Stresses in Butt Welding of Two Circular Pipes: An Experimental and Numerical Investigation

2014 ◽  
Author(s):  
Gurinder Singh Brar
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Welding Process ◽  
Diffraction Method ◽  
Element Model ◽  
X Ray Diffraction ◽  
X Ray

Welding is a reliable and efficient joining process in which the coalescence of metals is achieved by fusion. Welding is carried out with a very complex thermal cycle which results in irreversible elastic-plastic deformation and residual stresses in and around fusion zone and heat affected zone (HAZ). A residual stress due to welding arises from the differential heating of the plates due to the weld heat source. Residual stresses may be an advantage or disadvantage in structural components depending on their nature and magnitude. The beneficial effect of these compressive stresses have been widely used in industry as these are believed to increase fatigue strength of the component and reduce stress corrosion cracking and brittle fracture. But due to the presence of residual stresses in and around the weld zone the strength and life of the component is also reduced. To understand the behavior of residual stresses, two 10 mm thick Fe410WC mild steel plates are butt welded using the Metal Active Gas (MAG) process. An experimental method (X-ray diffraction) and numerical analysis (finite element analysis) were then carried out to calculate the residual stress values in the welded plates. Three types of V-butt weld joint — two-pass, three-pass and four-pass were considered in this study. In multi-pass welding operation the residual stress pattern developed in the material changes with each weld pass. In X-ray diffraction method, the residual stresses were derived from the elastic strain measurements using a Young’s modulus value of 210 GPa and Poisson’s ratio of 0.3. Finite element method based, SolidWorks software was used to develop coupled thermal-mechanical three dimension finite element model. The finite element model was evaluated for the transient temperatures and residual stresses during welding. Also variations of the physical and mechanical properties of material with the temperature were taken into account. The numerical results for peak transverse residual stresses attained in the welded plates for two-pass, three-pass and four-pass welded joint were 67.7 N/mm2, 58.6 N/mm2, and 48.1 N/mm2 respectively. The peak temperature attained during welding process comes out to be 970°C for two-pass weld, 820.8°C for three-pass weld and 651.9°C for four-pass weld. It can be concluded that due to increase in the number of passes during welding process or deposition weld beads, the residual stresses and temperature distribution decrease. Also, the results obtained by finite element method agree well with those from experimental X-ray diffraction method.

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.

Comparison of the hole-drilling and X-ray diffraction methods for measuring the residual stresses in shot-peened aluminium alloys

2005 ◽  
Vol 40 (2) ◽  
pp. 199-209 ◽  
Author(s):  
V Fontanari ◽  
F Frendo ◽  
Th Bortolamedi ◽  
P Scardi
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Surface Layer ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
Residual Stress Field ◽  
X Ray ◽  
Sources Of Uncertainty ◽  
Stress Profiles ◽  
Good Agreement

The incremental blind hole-drilling and the X-ray diffraction methods were used to measure the residual stress field introduced by shot peening in aluminium alloy 6082-T5 plates. Two peening treatments were selected to produce different depth extensions and peak values arising from different extents of plastic deformation in the surface layer. The results are discussed considering the various sources of uncertainty; in addition to the measuring technique, the effects of the surface treatment that usually induces a strong plastic deformation in the surface layer resulting in material work hardening and worsening of the surface morphology were considered. The residual stress profiles determined by the two methods showed quite good agreement for the two conditions, as regards the values both of the compressive peak and of the penetration depth. The present results provide mutual confirmation of the effectiveness of the two methods for the study of this class of materials.

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

2019 ◽  
Author(s):  
Ottaviano Grisolia ◽  
Lorenzo Scano ◽  
Francesco Piccini ◽  
Antonietta Lo Conte ◽  
Massimiliano De Agostinis ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Measurement ◽  
Numerical Models ◽  
Equivalent Stress ◽  
Welding Process ◽  
Diffraction Method ◽  
Hole Drilling ◽  
Creep Analysis ◽  
Maximum Residual Stress ◽  
American Standard

Abstract 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.

Shakedown During Fatigue of Residual Stresses Introduced by Different Mechanical Surface Treatments

2006 ◽  
Author(s):  
Christopher M. Gill ◽  
Philip J. Withers ◽  
Alex Evans ◽  
Neil Fox ◽  
Koichi Akita
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Glass Bead ◽  
Compressive Residual Stress ◽  
Cold Work ◽  
Diffraction Method ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
X Ray ◽  
Cold Worked

A layer of compressive residual stress extending from the surface of a component can help to extend fatigue life, but it must remain stable during applied service loading. Metal shot and glass bead peening are traditionally used; introducing a shallow (100–300μm) layer of compressive residual stress and a highly cold worked surface. Laser peening and deep rolling are capable of introducing much deeper compressive residual stresses combined with lower levels of cold work. In this paper we report on the level of shakedown of residual stress brought about by constant strain amplitude fatigue. Glass and metal shot peened, laser peened and deep rolled Ti-6Al-4V samples have been studied. The residual stress profiles as a function of depth have been measured using neutron diffraction, laboratory x-ray diffraction and a hybrid hole-drilling/laboratory x-ray diffraction method. The magnitude and depth of cold work determined for each of the treatment methods. The extent of subsequent residual stress shakedown under different strain amplitudes and load ratios, in deep rolled, glass bead and metal shot peened samples is also assessed.

scholarly journals Residual Stress Assessment of PWMT Butt Joint with 10mm HSLA S460G2+M Steel using HFMI/PIT FEA and XRD

2019 ◽  
Vol 269 ◽  
pp. 03010
Author(s):  
Noridzwan Nordin ◽  
Muhd. Faiz Mat ◽  
Yupiter H. P. Manurung ◽  
Salina Saidin ◽  
Dahia Andud
Keyword(s):  
Residual Stress ◽  
Diffraction Method ◽  
Butt Joint ◽  
Material Behavior ◽  
Actual Process ◽  
X Ray Diffraction ◽  
Butt Joints ◽  
Weld Toe ◽  
Good Agreement ◽  
Model Approach

This research involves the assessment of the residual stress of HSLA S460G2+M steel on butt joints which were welded using manual GMAW and further treated with HFMI/PIT process. The assessment began by manually welding 3-pass butt joint specimens using GMAW with ER80S-N1 as filler wire and mixed shielding gas (80%Ar-20%CO2). The weld toe of the specimens was then treated using HFMI/PIT operating at a peening frequency of 90Hz and a pneumatic pressure of 6 bar. The residual stress on the surface of treated and untreated specimens were measured using the X-ray diffraction method. Following the measurements, a simulation was conducted using non-linear solver FEA software MSC Marc/Mentat. The HFMI/PIT treatment process was simulated using a quasi-dynamic model approach for the force of the hammering pin. A customized spring function applying a consistent force onto the surface of the weld joint was modelled with this method. The material behavior model used for the specimen was based on a simplified Hensel-Spittel model obtained from the material database software MatILDa. It is observed that the HFMI/PIT-treated specimens induces compressive residual stress on the weld toe that is beneficial for fatigue life and the simulation demonstrated good agreement with the actual process.

scholarly journals Deformation Heterogeneity Study of a 6061-T6 Aluminum Alloy Processed by Equal Channel Angular Pressing

2017 ◽  
Vol 905 ◽  
pp. 40-45 ◽  
Author(s):  
Carlos Reyes-Ruiz ◽  
Igniasio A. Figueroa ◽  
Chedly Braham ◽  
Jose Maria Cabrera ◽  
Olivier Zanellato ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Equal Channel Angular Pressing ◽  
Bulk Material ◽  
X Ray Diffraction ◽  
Synchrotron Diffraction ◽  
Element Analysis ◽  
Angular Pressing ◽  
Strain Oscillations ◽  
Good Agreement

Among the severe plastic deformation techniques, the equal channel angular pressing (ECAP) has drastically improved the mechanical properties of the processed alloys. However, information regarding friction phenomenon, which modifies the deformation at the surface and the heterogeneity microstrain state produced by the process itself, is still scarce. In the present work, the deformation heterogeneity and the friction effect, at the surface in the bulk material of the 6061-T6 aluminum alloy processed by ECAP, is presented and discussed. The residual stress (RS) measurements were performed by means of X-Ray diffraction. By means of synchrotron diffraction, volumetric sections of the ECAPed samples were characterized. Finite element analysis showed a good agreement with the experimentally obtained residual stress and microhardness mapping results. The study also showed that the highest deformation zones were located at the outer parts of the deformed samples (top and bottom), while the inner zone showed strain oscillations of up to 49±2 MPa.

Surface Stress Measurement of Aluminum Alloy by X-Ray Diffraction Method

2011 ◽  
Vol 393-395 ◽  
pp. 343-348
Author(s):  
Shao Jie Wei ◽  
Kai Liao
Keyword(s):  
Aluminum Alloy ◽  
Stress Measurement ◽  
Mechanical Test ◽  
Diffraction Method ◽  
Surface Treatments ◽  
Hole Drilling ◽  
Grinding Wheel ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
X Ray

Surface residual stress distributions introduced by several surface treatments of 7075 aluminum alloy were acquired by non-destructive X-ray diffraction method. On the one hand, stress evolutions of the surface treated specimens were measured and analyzed to guide laboratory tests and engineering practices. On the other hand, the advantages of X-ray diffraction method in some test cases and reliability and accuracy of the measurements are discussed compared with the center hole-drilling method. The results show that X-ray method is flexible and accurate especially in measuring shallow surface layers stresses, which may be difficult or even be impossible to measure using traditional mechanical test methods. Different surface treatments introduce various distributed stresses and the latter treatment may remove the effects of the former one, so a practical treatment containing portable grinding wheel polishing, cross fine metallographic grinding machine polishing or low-speed milling, and mechanical polishing or electropolishing is suggested which can reduce the effects of external stresses introduced by surface treatments.

scholarly journals Numerical Assessment of Residual Stress Induced by Machining of Aluminum Alloy

2014 ◽  
Vol 996 ◽  
pp. 628-633 ◽  
Author(s):  
Naoufel Ben Moussa ◽  
Zouhayar Al-Adel ◽  
Habib Sidhom ◽  
Chedly Braham
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Diffraction Method ◽  
Numerical Approach ◽  
X Ray Diffraction ◽  
Near Surface ◽  
Finite Element Software ◽  
Surface Residual Stresses

A numerical approach has been developed to predict the near surface residual stresses induced by turning in orthogonal cutting configuration of aluminum alloy AA7075-T651. This approach is based on a Lagrangian formulation using the finite element software Abaqus–Explicit. The calculated residual stress profiles were validated by experimental measurements using X-ray diffraction method on samples turned under different cutting conditions. Using this method, the effect of the cutting speed and the feed on the machining residual stress has been established.

Residual Stress and Microstructures Characterization in Welded Al-Si-12Cu Alloy

2013 ◽  
Vol 856 ◽  
pp. 201-204
Author(s):  
Z. Boumerzoug ◽  
Chérifa Bouremel ◽  
V. Ji
Keyword(s):  
Residual Stress ◽  
Welded Joint ◽  
Dendritic Structure ◽  
Welding Process ◽  
Diffraction Method ◽  
Hardness Measurement ◽  
Optical Microscope ◽  
Stress Evolution ◽  
X Ray Diffraction ◽  
Isothermal Heat Treatments

X-ray diffraction method has been used to analyze the residual stress distribution across the joint of Al-Si-12Cu alloy just after welding process. On the other hand, isothermal heat treatments have been applied in order to study the residual stress evolution in this material. Optical microscope observation and Vickers hardness measurement have been carried out as complementary microstructure techniques. The different zones of welded joint have been analyzed, where the fusion zone was characterized by dendritic structure and different to heat affected zone. We have found a softening phenomenon in welded joint after heat according to microhardness results.

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