scholarly journals Assessment of the Contour Method for 2-D Cross Sectional Residual Stress Measurements of Friction Stir Welded Parts of AA2024-T3—Numerical and Experimental Comparison

Metals ◽  
2017 ◽  
Vol 7 (11) ◽  
pp. 508 ◽  
Author(s):  
Mads Sonne ◽  
Pierpaolo Carlone ◽  
Jesper Hattel
Keyword(s):  
Residual Stress ◽  
Contour Method ◽  
Experimental Comparison ◽  
Cross Sectional ◽  
Friction Stir ◽  
Stress Measurements

scholarly journals Residual Stress Measurements on a Metal Matrix Composite Using the Contour Method with Brittle Fracture

2014 ◽  
Vol 996 ◽  
pp. 349-354 ◽  
Author(s):  
Jeferson Araujo de Oliveira ◽  
Michael E. Fitzpatrick ◽  
Jan Kowal
Keyword(s):  
Residual Stress ◽  
Fatigue Crack ◽  
Brittle Failure ◽  
Metal Matrix ◽  
Crack Surface ◽  
Contour Method ◽  
Wire Edm ◽  
Stress Measurements ◽  
Fatigue And Fracture ◽  
Cut Surface

In this work we evaluate the application of the contour method to fatigue and fracture surfaces. Residual stress measurements were made on quenched and aged AA2124-SiCp composite using neutron diffraction, the contour method with wire EDM, and the contour method on a fatigue crack surface including brittle failure. The contour method successfully measured residual stresses from a wire electro-discharge cut surface, but the fracture method results suggest that residual stress information is lost due to plasticity during fatigue crack growth.

scholarly journals Cross-Sectional Mapping of Residual Stresses by Measuring the Surface Contour After a Cut

2000 ◽  
Vol 123 (2) ◽  
pp. 162-168 ◽  
Author(s):  
M. B. Prime
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Superposition Principle ◽  
New Method ◽  
Contour Method ◽  
Stress Profile ◽  
Relaxation Methods ◽  
Cross Sectional ◽  
Residual Stress Profile

A powerful new method for residual stress measurement is presented. A part is cut in two, and the contour, or profile, of the resulting new surface is measured to determine the displacements caused by release of the residual stresses. Analytically, for example using a finite element model, the opposite of the measured contour is applied to the surface as a displacement boundary condition. By Bueckner’s superposition principle, this calculation gives the original residual stresses normal to the plane of the cut. This “contour method” is more powerful than other relaxation methods because it can determine an arbitrary cross-sectional area map of residual stress, yet more simple because the stresses can be determined directly from the data without a tedious inversion technique. The new method is verified with a numerical simulation, then experimentally validated on a steel beam with a known residual stress profile.

An Efficient Modelling Approach for Predicting Residual Stress in Power-Beam Welds

2019 ◽  
Author(s):  
Graeme Horne ◽  
Danny Thomas ◽  
Andrew Collett ◽  
Andrew Clay ◽  
Martin Cott ◽  
...  
Keyword(s):  
Residual Stress ◽  
Structural Integrity ◽  
Welding Residual Stress ◽  
Contour Method ◽  
Element Analysis ◽  
Stress Measurements ◽  
316L Austenitic Stainless Steel ◽  
Important Input ◽  
Integrity Assessments ◽  
Modelling Approach

Abstract The prediction of welding residual stress in components is often an important input to structural integrity assessments. An efficient modelling approach was developed for predicting residual stress in power-beam welds, including validation against residual stress measurements. Specifically, sequentially coupled thermo-mechanical finite element analysis was conducted using a simplified heat source that was tuned to the observed fusion zone from a weld macrograph and thermocouple data for a series of electron beam welds in 316L austenitic stainless steel with a variety of geometries. The predicted residual stresses were compared with contour method and neutron diffraction residual stress measurements.

Residual Stress Measurements Revealing Weld Bead Start and Stop Effects in Single and Multi-Pass Weld-Runs

2005 ◽  
Author(s):  
Peter J. Bouchard ◽  
Javier R. Santisteban ◽  
Lyndon Edwards ◽  
Mark Turski ◽  
Jon James ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Weld Bead ◽  
Contour Method ◽  
Stress And Strain ◽  
Outer Diameter ◽  
End Effects ◽  
Stress Measurements ◽  
Stress Variations ◽  
Welding Direction

This paper describes transverse residual stress and strain measurements aimed at quantifying end effects in single and multi-pass weld-runs. Two test specimens are examined: a 60 mm long weld bead deposited on the surface of a 180 mm × 120 mm × 17 mm thick stainless steel plate, and a 62° arc-length multi-pass repair weld in a 432 mm outer diameter, 19.6 mm thick stainless steel pipe girth weld. The residual stress measurements were made by employing the relatively new Contour method and by neutron diffraction using ENGIN-X, the engineering spectrometer at the ISIS facility of the Rutherford Appleton Laboratory (UK). The measured underlying transverse residual stress levels are observed to be essentially uniform directly beneath the weld bead in the plate specimen and in the heat affected zone beneath the capping passes moving from mid-length towards the stop-end of the pipe repair. However, results from both test components demonstrate the existence of short-range concentrations of transverse residual stress along the welding direction owing to individual weld capping bead start and stop effects. Such short length-scale stress variations must be allowed for when interpreting residual stress measurements from line-scans. The experimental work also demonstrates the importance of knowing the expected stress or strain distribution prior to choosing measurement lines for detailed study. The Contour measurement method and neutron strain scanning are powerful tools for mapping residual stress and strain fields.

Characterization of a Plate Specimen From Phase I of the NRC/EPRI Weld Residual Stress Program

2011 ◽  
Author(s):  
Matthew Kerr ◽  
David L. Rudland ◽  
Michael B. Prime ◽  
Hunter Swenson ◽  
Miles A. Buechler ◽  
...  
Keyword(s):  
Residual Stress ◽  
Neutron Diffraction ◽  
Phase I ◽  
Nuclear Regulatory Commission ◽  
Contour Method ◽  
304L Stainless Steel ◽  
Fe Model ◽  
Stress Measurements ◽  
Weld Residual Stress ◽  
Plate Specimen

Time-of-flight neutron diffraction and contour method residual stress measurements were conducted at Los Alamos National Lab (LANL) on a lab sized plate specimen (P4) from Phase I of the joint U.S. Nuclear Regulatory Commission and Electric Power Research Institute Weld Residual Stress (NRC/EPRI WRS) program. The specimen was fabricated from a 304L stainless steel plate containing a seven pass Alloy 82 groove weld, restrained during welding and removed from the restraint for residual stress characterization. This paper presents neutron diffraction and contour method results, and compares these experimental stress measurements to a WRS Finite Element (FE) model. Finally details are provided on the procedure used to calculate the residual stress distribution in the restrained or as welded condition in order to allow comparison to other residual stress data collected as part of the EPRI lead Phase I WRS program.

Bounding Residual Stress Intensity Factor Profiles for Fracture Assessment of Pipe Girth Welds

2015 ◽  
Author(s):  
P. John Bouchard ◽  
Jino Mathew
Keyword(s):  
Residual Stress ◽  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Crack Size ◽  
Contour Method ◽  
Stress Measurements ◽  
Axial Residual Stress ◽  
Fracture Assessment ◽  
Girth Welds

The effect of residual stress on potential crack growth and fracture in welded structures is usually assessed through its contribution to the stress intensity factor (SIF) for the crack size and shape of interest. The idea of defining bounding residual SIF profiles for surface breaking circumferential cracks in pipe butt welds was presented at ASME PVP2013. The limiting profiles were based on through-thickness residual stress measurements for eight pipe girth welds. This paper presents new axial residual stress measurements made using the contour method for an Esshete 1250 stainless steel pipe girth weld. A wide variation in the through-wall distribution of axial residual stress around the circumference of the pipe is observed which has a significant effect on calculated values of SIF for postulated surface breaking circumferential cracks. Nonetheless, SIFs based on all of the new measurements (a total of 14 profiles) are comfortably bounded by the simple SIF prescriptions previously published.

Residual stress measurements in a thick, dissimilar aluminum alloy friction stir weld

2006 ◽  
Vol 54 (15) ◽  
pp. 4013-4021 ◽  
Author(s):  
M PRIME ◽  
T GNAUPELHEROLD ◽  
J BAUMANN ◽  
R LEDERICH ◽  
D BOWDEN ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Stress Measurements

Integrated FEM-DBEM Simulation of Crack Propagation in AA2024-T3 FSW Butt Joints Considering Manufacturing Effects

2015 ◽  
Vol 651-653 ◽  
pp. 877-882 ◽  
Author(s):  
Mads Rostgaard Sonne ◽  
Pierpaolo Carlone ◽  
Roberto Citarella ◽  
Jesper Henri Hattel
Keyword(s):  
Experimental Data ◽  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Crack Propagation ◽  
Crack Growth ◽  
Welding Process ◽  
Contour Method ◽  
Butt Joints ◽  
Friction Stir

This paper deals with a numerical and experimental investigation on the influence of residual stresses on fatigue crack growth in AA2024-T3 friction stir welded butt joints. An integrated FEM-DBEM procedure for the simulation of crack propagation is proposed and discussed. A numerical FEM model of the welding process of precipitation hardenable AA2024-T3 aluminum alloy is employed to infer the process induced residual stress field. The reliability of the FEM simulations with respect to the induced residual stresses is assessed comparing numerical outcomes with experimental data obtained by means of the contour method. The computed stress field is transferred to a DBEM environment and superimposed to the stress field produced by a remote fatigue traction load applied on a friction stir welded cracked specimen. Numerical results are compared with experimental data showing good agreement and highlighting the predictive capability of the proposed method. Furthermore, the influence of the residual stress distribution on crack growth is evidenced.

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