Measurement of Residual Stresses in Nuclear-grade Zircaloy-4(R) Tubes—Effect of Heat Treatment

Nuclear-grade Zircaloy-4(R) tubes are produced by a unique manufacturing process known as pilgering, which leaves the material in a work-hardened state containing a pattern of residual stresses. Moreover, such tubes exhibit elastic anisotropy as a result of the pilgering process. Therefore, standard equations originally proposed by Sachs (Z Met Kd, 19: 352–357, 1927; Sachs, Espey, Iron Age, 148: 63–71, 1941). for isotropic materials do not apply in this situation. Voyiadjis et al. (Exp Mech, 25: 145–147, 1985) proposed a set of equations for treating elastically anisotropic materials, but we have determined that there are discrepancies in their equations. In this paper, we present the derivation for a set of new equations for treating elastically anisotropic materials, and the application of these equations to residual stress measurements in Zr-4(R) tubes. To this end, through thickness distribution of residual stress components in as-received and heat treated (500°C) Zr-4(R) tubes was measured employing the Sachs’ boring-out technique in conjunction with electrochemical machining as the means of material removal, and our new equations. For both as-received and the heat treated materials, the axial and tangential residual stresses were significantly higher than the radial and shear residual stresses. The largest residual stress was the tangential stress component in the as-received material, showing a tensile value at the outer surface and a compressive value at the inner surface. At high values of von Mises equivalent stress, the principal directions of residual stress coincided with the principal axes of the tube for the as-received material, as well as for the material heat treated at 500°C.     

Stress measurement using vertically polarized shear waves

This paper proposes a method to evaluate surface stresses in orthotropic materials by the use of vertically polarized shear waves (SV waves). It is assumed that the normal to the surface coincides with one of the axes of anisotropy, and that the material anisotropy is not necessarily small. The speeds of the waves are expressed in terms of the material properties, the stress, the rigid body rotation and the propagation direction. From the expressions, and for the following two cases: (1) the rigid body rotation is known, (2) the anisotropy is weak, it is possible to determine the components of the surface stress by measuring the speeds of SV waves propagating in several directions. When the anisotropy is weak, the acoustoelastic birefringence for SV waves is also derived, to separate the material anisotropy and the difference of the principal stresses. The theory can be applied to stress evaluation by using ultrasonic Lamb waves whose speeds are nearly equal to those of SV waves.     

Program of experiments to determine the type of initial elastic anisotropy of material

A program of experiments to identify the type of elastic anisotropy of material is proposed. The position of the principal axes of material anisotropy is determined by measuring the strains resulting from compression of a cubic sample along three of its faces. For the subsequent identification of the type of anisotropy, samples oriented along definite principal axes are used.     

A simple plasticity model for prediction of non-coaxial flow of sand

A bounding surface plasticity model for non-coaxiality, another aspect of anisotropic behavior of sands under rotation of principal stress axes; is developed in the critical state framework. Numerous experimental evidences exist that corroborate dependence of plastic shear strain rate direction on inherent fabric anisotropy. At first, general expressions for plastic strain rate with respect to possible emerge of non-coaxial flow are obtained. Consequently, using an anisotropy state parameter that is specially developed for this model and accounts for the interaction between imposed loading and soil fabric; effect of anisotropy on plastic flow direction is taken into account. Besides, novel circumstances are proposed for plastic modulus and dilatancy under rotation of principal stress axes. Finally, it is shown that the model is able to simulate successfully the non-coaxial behavior of sands subjected to principal stress axes rotation.     

Homogenization problems of a hollow cylinder made of elastic materials with discontinuous properties

In this paper, we present the homogenization of an anisotropic hollow layered tube with discontinuous elastic coefficients. We focus on some aspects of technological importance, such as the effective coefficients of anisotropic materials, the behavior of the homogenized displacements and stresses, the discontinuities of in-plane shear, hoop and longitudinal stresses, the homogenization-induced anisotropy in the isotropic case. We conclude that the problem of cylindrically anisotropic tubes under extension, torsion, shearing and pressuring is stable by homogenization and we define the effective tensor of the material elastic coefficients. Some numerical examples confirm the theoretical results.     

Determination of All 21 Independent Elastic Coefficients of Generally Anisotropic Solids by Resonant Ultrasound Spectroscopy: Benchmark Examples

We present an experimental methodology for determination of all 21 elastic constants of materials with general (triclinic) anisotropy. This methodology is based on contactless resonant ultrasound spectroscopy complemented by pulse-echo measurements and enables full characterization of elastic anisotropy of such materials from measurements on a single small specimen of a parallelogram shape. The methodology is applied to two benchmark examples: a material with generally rotated cubic anisotropy (single crystal of silicon) and an isotropic material (silicon-infiltrated silicon carbide ceramics). In both the proposed approach is able to provide a full triclinic tensor with relatively low experimental errors and to identify indubitably the anisotropy class of the material; for the cubic material also the orientations of the principal axes and the cubic elastic coefficients are reliably determined.     

Residual-stress measurement in SS304 seamless tube

This paper involves the experimental measurement of residual stresses in a nonwelded nuclear-grade 304 stainless-steel seamless tube subjected to one-sided quenching of its outside surface. Because this grade of tube is used extensively in nuclear power plants, the residual stresses measured are of interest to the nuclear industry. The Sach's boring method was used to obtain residual stresses. The longitudinal and tangential residual stresses at the inner wall were found to be 69 MPa to 138 MPa compressive. The results indicate that the residual-stress distribution would allow the tube to be highly resistant to the formation and propagation of stress-corrosion cracks.     

Analysis of axially symmetrical residual stresses in bars and tubes

A new method has been developed for the determination of residual stresses in a cylinder. Boring out or removing layers from outside induces changes in the length and diameter of the remaining bar. The initial distributions of the stresses are derived from measurements of the length change only. Details of equations required for the calculations are described. The method rests on an assumption that the radial displacement just below a surface is equal to the radial displacement at a new surface after removal of the surface layer of material. This assumption leads to relations between the three residual-stress components. The numerical calculations of these relations agree well with the experimental data for quenched cylinders obtained by using the Sachs method in other investigations. A brief general discussion is given on the equilibrium conditions of the residual stresses determined.     

Basis free relations for the conjugate stresses of the strains based on the right stretch tensor

In this paper, general relations between two different stress tensors T^f and T^g, respectively conjugate to strain measure tensors f(U) and g(U) are found. The strain class f(U) is based on the right stretch tensor U which includes the Seth–Hill strain tensors. The method is based on the definition of energy conjugacy and Hill’s principal axis method. The relations are derived for the cases of distinct as well as coalescent principal stretches. As a special case, conjugate stresses of the Seth–Hill strain measures are then more investigated in their general form. The relations are first obtained in the principal axes of the tensor U. Then they are used to obtain basis free tensorial equations between different conjugate stresses. These basis free equations between two conjugate stresses are obtained through the comparison of the relations between their components in the principal axes, with a possible tensor expansion relation between the stresses with unknown coefficients, the unknown coefficients to be obtained. In this regard, some relations are also obtained for T⁽⁰⁾ which is the stress conjugate to the logarithmic strain tensor lnU.     

Contact Problem for an Elastic Orthotropic Half-Strip

The paper discusses the problem on a rigid flat-based die forced into a half-strip. The material of the half-strip, whose semiinfinite sides are fixed, is orthotropic; the principal axes of anisotropy coincide with the Cartesian coordinate axes. Friction between the die and the half-strip is taken into account. The problem is solved by an asymptotic method developed by the authors. Some numerical results are presented     

Unit cell debonding analyses for arbitrary orientation of plastic anisotropy

Debonding of rigid inclusions embedded in the elastic–plastic aluminum alloy Al 2090-T3 is analyzed numerically using a unit cell model taking full account of finite strains. The cell is subjected to overall biaxial plane strain tension and periodical boundary conditions are applied to represent arbitrary orientations of plastic anisotropy. Plastic anisotropy is considered using two phenomenological anisotropic yield criteria, namely Hill [Proceedings of the Royal Society of London A 193 (1948) 281] and Barlat et al. [International Journal of Plasticity 7 (1991) 693]. For this material plastic anisotropy delays debonding compared to plastic isotropy except for the case of Hill’s yield function when the tensile directions coincided with the principal axes of anisotropy. For some inclinations of the principal axes of anisotropy relative to the tensile directions, the stress strain responses are identical but the deformation modes are mirror images of each other.     

Homogenization of a pressurized tube made of elastoplastic materials with discontinuous properties

In this paper we present the homogenization of a periodic multilayered pressurized tube made of very dissimilar elastoplastic materials. We focus on some aspects of technological importance, such as the effective properties, the behavior of the homogenized displacements and stresses, the discontinuities of hoop and longitudinal stresses, the homogenization-induced anisotropy. We conclude that the problem needs to be reformulated in order to be stable by homogenization and we define the effective elastic and incremental stress corrector matrices for the incremental stress–total strain matrix law. Finally, we present the numerical simulation for both the non-homogeneous and the homogenized material and two numerical examples confirming the theoretical results.     

Numerical simulation of welding induced damage and residual stress of martensitic steel 15-5PH

This paper is about the modeling of damage and residual stresses induced by a complex history of thermo-elasto-plastic multiphase in welding heat affected zone (HAZ). A two-scale model for elasto-plastic damaged multiphase is developed. The constitutive equations of the model are coupling ductile damage, elasto-plastic strains, phase transformation and transformation plasticity. In this study, an equation of damage evolution is proposed based on the continuum damage mechanics. In order to validate the proposed damage evolution, a set of flat notched bars with various notches are to simulated and then compared to experimental results. An example of laser heated disk is simulated to elaborate the two-scale model and the simulated results of the two-scale model in CAST3M^® is compared the results calculated by a homogenized macroscopic model in SYSWELD^®. The study shows the two-scale model provides valuable freedom to choose the material or mechanical law for each phase. The proposed damage equation extends the application of existing ductile damage models. In the calculation of residual stresses, damage decreases the residual stresses in HAZ by a small amount.     

Finite strain analysis of simple shear using recent anisotropic yield criteria

The finite strain response of a rectangular block subjected to constrained simple shearing deformations is considered in order to evaluate the predictive capability of some recently proposed anisotropic yield functions. It is shown that, in the presence of plane anisotropy, the prediction of realistic second order normal stresses cannot be expected since every different initial orientation of the material axes relative to the loading axes results in a different response due to the rotation of the material axes with shear. Parametric studies are performed in order to determine possible limits on the material constants so that the predicted normal stresses remain second order with respect to the shear stress itself. Our numerical results indicate that, in particular, the commonly employed range of one parameter associated with grain related anisotropy renders results which no longer imply predicting a proper second order effect but rather introduces errors of the first order. The results suggest that the modelling of anisotropy with such phenomenological anisotropic yield functions should be limited to near-quadratic yield surfaces for applications involving stress states outside the biaxial tensile stress range.     

Residual-stress determination of concentric layers of cylindrically orthotropic materials

Equations have been obtained for determining residual stresses in the wall of a hollow, axially symmetric body consisting of concentric layers of elastically dissimilar materials, all having cylindrical elastic orthotropy. These equations permit residual normal stresses in the radial, circumferential, and axial directions and residual shear stresses on planes normal to the axis of the body to be calculated from measurements of the strains developed on the inner or outer cylindrical surface of the body as thin layers of stressed material are serially removed from the outer or inner surfaces, respectively. The equations are applied to a parametric study of stresses in an elastically isotropic, two-component body to determine the nature of the differences in stresses between the composite body and a homogeneous body as a function of the difference in elastic constants.     

Effects of magnetic field,porosity, and wall properties for anisotropically elastic multi-stenosis arteries on blood flow characteristics

A mathematical model for blood flow through an elastic artery with multistenosis under the effect of a magnetic field in a porous medium is presented. The considered arterial segment is simulated by an anisotropically elastic cylindrical tube filled with a viscous incompressible electrically conducting fluid representing blood. An artery with mild local narrowing in its lumen forming a stenosis is analyzed. The effects of arterial wall parameters represent viscoelastic stresses along the longitudinal and circumferential directions T _t and T _θ , respectively. The degree of anisotropy of the vessel wall γ, total mass of the vessel, and surrounding tissues M and contributions of the viscous and elastic constraints to the total tethering C and K respectively on resistance impedance, wall shear stress distribution, and radial and axial velocities are illustrated. Also, the effects of the stenosis shape m, the constant of permeability X, the Hartmann number H _α and the maximum height of the stenosis size δ on the fluid flow characteristics are investigated. The results show that the flow is appreciably influenced by surrounding connective tissues of the arterial wall motion, and the degree of anisotropy of the vessel wall plays an important role in determining the material of the artery. Further, the wall shear stress distribution increases with increasing T _t and γ while decreases with increasing T _θ , M, C, and K. Transmission of the wall shear stress distribution and resistance impedance at the wall surface through a tethered tube are substantially lower than those through a free tube, while the shearing stress distribution at the stenosis throat has inverse characteristic through totally tethered and free tubes. The trapping bolus increases in size toward the line center of the tube as the permeability constant X increases and decreases with the Hartmann number Ha increased. Finally, the trapping bolus appears, gradually in the case of non-symmetric stenosis, and disappears in the case of symmetric stenosis. The size of trapped bolus for the stream lines in a free isotropic tube (i.e., a tube initially unstressed) is smaller than those in a tethered tube.     

An acoustoelastic method for measuring residual stresses in slightly orthotropic materials

An acoustoelastic method for residual stress measurement in slightly orthotropic materials by using ultrasonic longitudinal and shear waves is presented. A shear transducer with small vibrator 2 × 2mm² is developed and described, and the measurement of 2-D residual stresses in a seam welded plate was carried out by this method with the shear transducer developed.This project was supported by National Natural Science Fundation of China     

A Pressurized Functionally Graded Hollow Cylinder with Arbitrarily Varying Material Properties

The elastic analysis of a pressurized functionally graded material (FGM) annulus or tube is made in this paper. Different from existing studies, this study deals with an axisymmetrical FGM hollow cylinder or disk with arbitrarily varying material properties. A simple and efficient approach is suggested, which reduces the associated problem to solving a Fredholm integral equation. The resulting equation is approximately solved by expanding the solution as series of Legendre polynomials. The stresses and displacements can be represented in terms of the solution to the equation. For radius-dependent Young’s modulus, numerical results of the distribution of the radial and circumferential stresses are presented graphically. Our results indicate that change in the gradient of the FGM tube does not produce a substantial variation of the radial stress, but strongly affects the distribution of the hoop stress. In particular, the hoop stress may reach its maximum at an internal position or at the outer surface when the tube is internally pressurized. The results obtained are helpful in designing FGM cylindrical vessels to prevent failure.      

Inversion for weak triclinic anisotropy from acoustic axes

Acoustic axes are directions in anisotropic elastic media, in which phase velocities of two or three plane waves (P$P$, S1$S1$ or S2$S2$ waves) coincide. Acoustic axes are important, because they can cause singularities in the field of polarization vectors and anomalies in the shape of the slowness surface. The maximum number of acoustic axes in triclinic anisotropy is 16, and their directions depend on anisotropy parameters in a complicate way. Under weak anisotropy approximation this dependence simplifies and the directions of acoustic axes can be used for the inversion for anisotropy parameters. The maximum acoustic axes under weak anisotropy is 16, the minimum number of acoustic axes is zero. In the inversion, we can retrieve 13 combinations of anisotropy parameters provided we use directions of 7 acoustic axes at least. Under weak anisotropy approximation, the directions of acoustic axes are insensitive to strength of anisotropy; hence we cannot invert for absolute values of weak anisotropy parameters, but only for their relative values. Numerical tests have shown that the inversion is applicable only to very weak anisotropy with strength of less than 5%, provided that the acoustic axes used in the inversion are determined with an accuracy of 0.1^°$0.1^{°}$ or better. In this case the inversion yields an average error for elastic parameters of less than 10%. In order to invert for the total set of 21 anisotropy parameters it is necessary to combine the measurements of the directions of the acoustic axes with measurements of other attributes of elastic waves in anisotropic media.