Simulation and Measurement of Residual Stresses in a Type 316H Stain­less Steel Offset Repair in a Pipe Girth Weld

2011 ◽  
Vol 681 ◽  
pp. 492-497 ◽  
Author(s):  
M.S. Hossain ◽  
D.M. Goudar ◽  
Christopher E. Truman ◽  
David John Smith
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Stress Measurement ◽  
Mechanical Strain ◽  
Measurement Procedure ◽  
Hole Drilling ◽  
Residual Stress Field ◽  
Experimental Procedure ◽  
Stainless Steel Pipe ◽  
Elastic Inversion

In common with all mechanical strain relief residual stress measurement methods, extra care must be taken when making measurements on components containing highly triaxial residual stress fields which are close to yield. The introduction of a free surface, created as part of the measurement procedure, can lead to plastic redistribution of the residual stress field. Usually, this is not accounted for in the elastic inversion algorithms of the experimental procedure. This paper demon­strates the usefulness and accuracy of deep-hole drilling (DHD) method [1] in a component predicted to contain a triaxial residual stress field. Previous measurements [2] are compared with the results of a DHD simulation on a type 316H stainless steel pipe containing a repair weld offset from an original girth weld. The influence of different material models was also studied.

Residual Stress Measurement Simulation in a Type 316 Stainless Steel Girth-Butt Weld Joint

2008 ◽  
Author(s):  
S. Hossain ◽  
C. E. Truman ◽  
D. J. Smith ◽  
K. Ogawa
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Stress Field ◽  
Residual Stresses ◽  
Weld Joint ◽  
Stress Measurement ◽  
Measurement Procedure ◽  
Residual Stress Measurement ◽  
Residual Stress Field ◽  
Butt Weld

Several techniques exist to measure residual stresses, but most only work close to the surface of a component. The deep-hole drilling (DHD) method [1] provides complete, through-thickness, measurements of residual stress with high spatial resolution which can be used to validate numerical models. In common with all mechanical strain release methods of residual stress measurement, extra care must be taken when making measurements on components containing highly triaxial residual stress fields which are close to yield. This is because the introduction of a free surface, created as part of the measurement procedure, can lead to plastic redistribution of the residual stress field which is not accounted for in the elastic inversion algorithms of the experimental procedure. This paper seeks to demonstrate the usefulness and accuracy of the DHD method in a component predicted to contain a triaxial residual stress field by comparing measurements and the results of a DHD simulation on a type 316 stainless steel pipe with girth-butt weld joint. Step 1, results are presented from three-dimensional finite element (FE) simulations of the original girth weld. Step 2, the residual stresses predicted from these simulations are mapped onto a new mesh, designed in order to permit a simulation of the DHD measurement method detailed above. Step 3, an FE simulation of the DHD procedure was undertaken, and the predictions of the radial distortion of the initial reference hole were used in the usual experimental inversion algorithm. This permitted a simulation of the DHD measured residual stresses to be obtained and compared with the predictions of the initial FE model. The effects of different material models as well as the measurement paths were also considered. Finally, step 4, FE predicted residual stresses, DHD simulated residual stresses and actual DHD measured residual stresses were compared and conclusions concerning the accuracy of the DHD measurement procedure were made.

AL7N01 Butt Joint Welding Residual Stress Measurement by Ultrasonic Method

2012 ◽  
Vol 468-471 ◽  
pp. 476-479
Author(s):  
Zi Qi Ma ◽  
Xue Song Liu ◽  
Yi Cheng ◽  
Liang Zhang ◽  
Jian Gang Shi ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Spatial Resolution ◽  
Stress Measurement ◽  
Ultrasonic Method ◽  
Differential Method ◽  
Welding Residual Stress ◽  
Residual Stress Measurement ◽  
Hole Drilling ◽  
Residual Stress Field

Analysis the shortage of ultrasonic stress measurement based on Lcr wave in low spatial resolution. Point out it is inapplicable in measuring gradient stress field like welding residual stress field. In this paper, propagation differential method is proposed to solve the low spatial resolution problem on Lcr wave stress measurement, and its theory is introduced. This method can raise the spatial resolution from tens of millimeter to a several millimeter level with out decline the stress resolution. A welding residual stress field of 7N01 aluminum alloy butted joint plate is measured by this method, and its result is compared with hole drilling method. Source of errors is discussed. It is seen that propagation differential method is applicable in welding residual stress measurement.

Finite Element Validation of the over-Coring Deep-Hole Drilling Technique

2011 ◽  
Vol 70 ◽  
pp. 291-296 ◽  
Author(s):  
Sayeed Hossain ◽  
Ed J. Kingston ◽  
Christopher E. Truman ◽  
David John Smith
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stress Field ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Residual Stress Measurement ◽  
Hole Drilling ◽  
Deep Hole ◽  
Residual Stress Field ◽  
Deep Hole Drilling

The main objective of the present study is to validate a simple over-coring deep-hole drilling (oDHD) residual stress measurement technique by utilising finite element simulations of the technique. A number of three dimensional (3D) finite element analyses (FEA) were carried out to explore the influence of material removal and the cutting sequence during the deep-hole drilling (DHD) residual stress measurement process on the initial residual stress field. Two models were considered in the study. First, the residual stress field predicted in a rapid spray water quenched solid cylinder was used as the initial stress field for the DHD FE model. The DHD reconstructed residual stresses were compared with the initial FE predicted stresses. Different cutting sequences and different dimensions were systematically simulated before arriving at an optimum solution for the oDHD technique. The oDHD technique significantly improved the spatial resolution and was applied in a second model consisting of a 40mm thick butt-welded pipe. The DHD reconstructed residual stresses compared very well with the initial FE predicted weld residual stress thereby validating the oDHD technique.

Macro-Residual Stress Field Retrieval for Predicting the Machining Deformation of Non-Prestretched Plate

2011 ◽  
Vol 317-319 ◽  
pp. 386-392
Author(s):  
Yin Fei Yang ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Large Scale ◽  
Hole Drilling ◽  
Residual Stress Field ◽  
Hole Drilling Method ◽  
Machining Deformation ◽  
Stress Changes ◽  
Drilling Method ◽  
And Control

The unknown and uneven macro-residual stresses in blanks will cause deformation on large-scale component, especially in non-prestretched plates. Based on the retrieval of stress field by measuring stress changes due to the rebalance of stresses after machining, a new idea is proposed in this paper to predict and control the machining deformation of large-scale components. It consists of analysis of the machining deformation, retrieval of macro-residual stress field, and finally optimization of following cutting process. In the retrieval process, the stresses are measured with an improved hole-drilling method and the measured data are then interpolated to 3D stress field.

Characterisation of the Residual Stress Field and Mechanical Properties of a Narrow-Gap Girth-Welded Stainless Steel Pipe and Subsequent Application to a Numerical Model

2011 ◽  
Author(s):  
Robert J. A. McCluskey ◽  
Andrew H. Sherry ◽  
Martin R. Goldthorpe
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Stainless Steel ◽  
Stress Field ◽  
Steel Pipe ◽  
Primary Circuit ◽  
Narrow Gap ◽  
Residual Stress Field ◽  
Butt Weld ◽  
Stainless Steel Pipe

Girth-butt welds are used to join sections of stainless steel pipe in the primary circuit of Pressurised Water Reactors. The welding process creates residual stress fields across the weldment, which can contribute to the crack driving force when a defect is present. Assessment procedures account for such defects, enabling safety justifications to be made for continued operation of nuclear power plant. Such procedures require the size and nature of the residual stress field to be determined in order to make reliable structural integrity assessments. This paper describes the investigation of the residual stress field and fracture behaviour of a recently developed narrow-gap 304-stainless steel girth-butt weld in a primary circuit pipe. Two residual stress measurement techniques, Neutron Diffraction (ND) and incremental Deep Hole Drilling (iDHD), were used to measure the original residual stress field in the pipe weld. A second pipe weld specimen was used to fabricate tensile and fracture toughness specimens from which the mechanical properties of the weld material were determined. The residual stress and mechanical test data were used to develop numerical models of the pipe weld containing a postulated circumferential defect under an applied axial load. The numerical simulation results were applied within a failure assessment diagram, comparing different interaction parameters on the prediction of component failure load.

Measurement of Residual Hoop Stresses in Cylinders Using the Compliance Method

1986 ◽  
Vol 108 (2) ◽  
pp. 87-92 ◽  
Author(s):  
Weili Cheng ◽  
Iain Finnie
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Hoop Stress ◽  
Axial Stress ◽  
Hole Drilling ◽  
Residual Stress Field ◽  
Axial Coordinate ◽  
X Ray ◽  
Axial Crack ◽  
Hoop Stresses

A method is proposed for measurement of the hoop stress in an axisymmetric residual stress field in cylinders in which the axial stress is independent of the axial coordinate. The method involves measuring strains at the outside surface while an axial crack is cut progressively from the outside. Experimental results are presented for two short cylindrical rings cut from a long quenched cylinder. Good general agreement is obtained with X-ray and hole drilling measurements of residual stresses.

Assessment of non-uniform residual stress field of the thermal sprayed stainless steel coatings on aluminium substrates by the integral hole drilling method

2020 ◽  
pp. 095440622091771
Author(s):  
Harouche Mohamed Karim ◽  
Hattali Lamine ◽  
Mesrati Nadir
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Stress Field ◽  
Residual Stresses ◽  
Bond Coat ◽  
High Pressures ◽  
Hole Drilling ◽  
Arc Spraying ◽  
Residual Stress Field ◽  
Stainless Steel Coatings

Thermal spray is one of the most used techniques to produce coatings on structural materials. Such coatings are used as protection against high temperatures, corrosion, erosion and wear. The combined action of high pressures, temperatures and spraying conditions give rise to non-uniform residual stresses. The latter plays an important role in coating design and process parameters optimization. The present work highlights the influence of coatings thickness on the evolution of residual stresses in layered materials. Therefore, thick stainless steel coatings (ASTM 301) of different thicknesses are manufactured by wire arc spraying on aluminium alloy substrates (ASTM 2017A). For a better bond strength, a Ni–Al bond coat is first deposited. Furthermore, a numerically supported hole drilling strain gage method for residual stress field evaluation is proposed. Required calibration coefficients, for the strain–stress transformation formalism based on the integral method, are computed through finite element calculations using Abaqus software. The results indicate that the maximum residual stresses, for all thicknesses, are tensile and range from 140 to 275 MPa. The bond coat does not seem to affect the stress field. Also, it was found that the mean equivalent Von-Mises stress decreases with increasing coating thickness; hence reducing the interfacial adhesion energy of the sprayed materials.

Uncertainties in Triaxial Residual Stress Measurements

2011 ◽  
Vol 681 ◽  
pp. 498-503 ◽  
Author(s):  
D.M. Goudar ◽  
M.S. Hossain ◽  
Christopher E. Truman ◽  
Ed J. Kingston ◽  
David John Smith
Keyword(s):  
Residual Stress ◽  
Error Analysis ◽  
Cold Water ◽  
Stress Measurement ◽  
Measurement Techniques ◽  
Mechanical Strain ◽  
Hole Drilling ◽  
Stress Distributions ◽  
Deep Hole ◽  
Deep Hole Drilling

Residual stress measurement techniques using mechanical strain relaxation depend on a number of physical quantities and are therefore sensitive to errors associated with the measured data. The resulting stress uncertainties can easily become significant and compromise the usefulness of the results or lead to misinterpretation of the behaviour of the residual stress distributions. It is therefore essential to develop an error analysis procedure for the measurements undertaken. Error analysis procedures for the deep hole drilling (DHD) method are developed to consider triaxial residual stresses. A modified deep hole drilling method, called the incremental deep-hole drilling (iDHD), was applied to measure the near yield residual stress distributions in a cold water quenched aluminium 7010 alloy forged block. The experimental results are used to illustrate the errors.

scholarly journals Characterisation of Residual Stress due to Fillet Rolling on Bolts Made of a Nickel Base Superalloy

2014 ◽  
Vol 996 ◽  
pp. 670-675 ◽  
Author(s):  
Wei Li ◽  
Shu Yan Zhang ◽  
Saurabh Kabra ◽  
Anton Tremsin ◽  
Brian Abbey ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Compressive Residual Stress ◽  
Hole Drilling ◽  
Nickel Base Superalloy ◽  
Residual Stress Field ◽  
Neutron Transmission ◽  
Incremental Hole Drilling ◽  
Nickel Base ◽  
Base Superalloy

This paper investigates residual stress due to fillet rolling on bolts made of ATI 718Plus® superalloy. Incremental hole drilling, neutron diffraction and neutron transmission have been used to assess residual stress near the bolt head fillet. A compressive residual stress field was identified in the first 0.5 mm from the surface. Post fillet rolling solution anneal can relieve the residual stress at the fillet.

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