Residual Stress Analysis on Thick Film Systems by the Incremental Hole-Drilling Method – Simulation and Experimental Results

The residual stress state in thick film systems, as for example thermal spray coatings, is crucial for many of the component’s properties and for the evaluation of the integrity of the coating under thermal and/or mechanical loading. Therefore it is necessary to be able to determine the local residual stress distribution in the coating, at the interface and in the substrate. The incremental hole-drilling method is a widely used method for measuring residual stress depth profiles, which was already applied for thermally sprayed coatings. But so far no reliable hole-drilling evaluation method exists for layered materials having a stress gradient in depth. The objective was to investigate, how far existing evaluation methods of the incremental hole-drilling method that are only valid for residual stress analysis of homogenous material states can be applied to thick film systems with coating thicknesses between 50 μm and 1000 μm and to point out the application limits for these already existing methods. A systematic Finite Element (FE) study was carried out for coating systems with an axisymmetric residual stress state σ₁?=?σ₂. It is shown that conventional evaluation methods developed for homogeneous, non-layered material states can be successfully applied for a stress evaluation in the substrate and the coating for small and for sufficiently large coating thicknesses, respectively, regardless of the type of evaluation algorithm used i.e. the differential or the integral method. The same accounts for material combinations that have a Young’s modulus ratio close to one, between 0.8 and 1.2. The studies indicated that outside the given ranges case specific calibration must be applied to calculate reliable results. Further, calibration data were determined case specifically for a selected model coating system. The accuracy of a residual stress determination using these case specific calibration data was examined and the sensitivity of the evaluation with respect to an accurate knowledge of the boundary conditions of the coating system i.e. the coating thickness and the Young modulus was studied systematically. Finally, the calibration data were applied on a thermally sprayed aluminium coating on a steel substrate analysis and the results for using the incremental hole drilling method were compared to results from X-ray stress analysis.     

Plasticity Effects in the Hole-Drilling Residual Stress Measurement in Peened Surfaces

The incremental hole-drilling technique (IHD) is a widely established and accepted technique to determine residual stresses in peened surfaces. However, high residual stresses can lead to local yielding, due to the stress concentration around the drilled hole, affecting the standard residual stress evaluation, which is based on linear elastic equations. This so-called plasticity effect can be quantified by means of a plasticity factor, which measures the residual stress magnitude with respect to the approximate onset of plasticity. The observed resultant overestimation of IHD residual stresses depends on various factors, such as the residual stress state, the stress gradients and the material’s strain hardening. In peened surfaces, equibiaxial stresses are often found. For this case, the combined effect of the local yielding and stress gradients is numerically and experimentally analyzed in detail in this work. In addition, a new plasticity factor is proposed for the evaluation of the onset of yielding around drilled holes in peened surface layers. This new factor is able to explain the agreement and disagreement found between the IHD residual stresses and those determined by X-ray diffraction in shot-peened steel surfaces.     

考虑塑性和刚度不匹配的焊接残余应力估算

现有残余应力计算方法未能考虑材料塑性变形和焊接接头刚度不匹配的影响,使得焊接残余应力计算结果和实际残余应力存在较大偏差.在2219-T87铝合金钨极氩弧焊焊接头残余应力测试基础上,提出一种基于非线性有限元和材料弹性模量分区的残余应力—释放应变曲线的残余应力计算方法,研究了材料塑性变形和接头刚度不匹配对焊接残余应力计算的影响.结果表明,焊接接头中非均质材料塑性不匹配可以引起对于残余应力计算的较大误差;材料塑性变形对残余应力的影响大于接头刚度不匹配对残余应力的影响.所提出方法修正了传统方法在焊接接头的残余应力计算中由于未考虑接头非均质材料塑性不匹配而引起的误差.     

Anisotropic plastic deformation of extruded aluminum alloy tube under axial forces and internal pressure

The anisotropic plastic deformation behavior of extruded 5000 series aluminum alloy tubes, A5154-H112, of 76 mm outer diameter and 3.9 mm wall thickness is investigated, using a servo-controlled tension-internal pressure testing machine. This machine is capable of applying arbitrary stress or strain paths to a tubular specimen using an electrical, closed-loop control system. Detailed measurements were made of the initial yield locus, contours of plastic work for different levels of work-hardening, and the directions of the incremental plastic strain vectors for both linear and combined stress paths. It is found that the measured work contours constructed in the principal stress space are similar in shape, and that the directions of the incremental plastic strain vectors remain almost constant at constant stress ratios. The work-hardening behavior predicted using Hosford's or the Yld2000-2d yield functions under the assumption of isotropic hardening agrees closely with the observations for both linear and combined stress paths. The material is thus found to work-harden almost isotropically. Both yield functions are effective phenomenological plasticity models for predicting the anisotropic plastic deformation behavior of the material.     

Incremental Computation Technique for Residual Stress Calculations Using the Integral Method

The Integral Method for determining residual stresses involves making surface deformation measurements within a sequence of small increments of material removal depth. Typically, the associated matrix equation for solving the residual stresses within each depth increment is ill-conditioned. The resulting error sensitivity of the residual stress evaluation makes it essential that data measurement errors are minimized and that the residual stress solution method be as stable as possible. These two issues are addressed in this paper. The proposed method involves using incremental deformation data instead of the total deformation data that are conventionally used. The technique is illustrated using an example ESPI hole-drilling measurement.     

On the measurement of residual-stress gradients in aluminum-alloy specimens

The assessment or prediction of fatigue life or strength improvement due to residual stresses requires knowledge of their magnitude and distribution. This paper presents an extension of the modified hole-drilling technique (MHDT) to the measurement of stress gradients in a biaxial-residual-stress field. This is achieved by taking a series of ‘point’ measurements and evaluating the stress profile with due consideration to the effects of hole location, the interaction between holes and the redistribution of stress due to hole drilling. An application to the measurement of residual stresses induced in 2024-T3 aluminum-alloy specimens by edge-dimpling technique is described and the method of compensation for the effect of redistribution of stress is explained. The experimental results are shown to be in good agreement with those obtained elsewhere by an analytic-numerical solution.     

Validation of Mechanical Strain Relaxation Methods for Stress Measurement

Most validation studies of mechanical strain relaxation (MSR) methods for residual stress measurement rely on using the saw-tooth residual stress distribution resulting from four point bending and elastic–plastic deformation. Validation studies using simple applied stress profiles in rectangular steel beams are used in this work, together with beams subjected to elastic–plastic bending. Two MSR methods are explored, deep-hole drilling (DHD) and incremental centre hole drilling (ICHD). As well as a series of experiments, finite element analyses are conducted to determine the accuracy in the inversion of measured deformation to reconstruct stress. The validation tests demonstrated that apart from the applied stresses, the initial residual stresses also contribute even when samples are expected to be stress free. The uncertainty in measurement for the two MSR methods is determined, with the uncertainty in near surface measurement found to be significantly larger than uncertainty for interior measurement. In simple loading cases (and simple stress profiles) the uncertainty in measurement and hence the degree of validation is shown to be within about ±50 MPa for steel for “known” stress up to about 140 MPa. However, if the residual stress distribution is more complex there arises increased uncertainty in the predicted residual stress and lack of confidence between measurements methods.     

Evaluation of the High-Speed Drilling Technique for the Incremental Hole-Drilling Method

The incremental hole-drilling method is frequently used for residual stress depth distribution analyses, due to its fast and economical experimental execution. Depending on the planned use of the component, the drilled hole that is made to measure the residual stress can often be repaired or ignored if it does not affect the intended use of the part. Nevertheless an important experimental issue and assumption is the introduction of an ideal cylindrical hole into the component without additional plastic deformation. Although high-speed drilling is well established the consequences of the resulting hole geometries compared to ideal assumptions are not well known. Therefore, a detailed comparison between different bits and drilling techniques was carried out and is discussed in this paper in order to detect the best experimental conditions and to find out reasons especially for the lack of accuracy of the hole-drilling method for the first increments close to the specimens surface. It comes out that the orbital drilling with common used six-blade bits results in the best compromise of an ideal cylindrical hole and centricity to the center of the strain gage rosette. In the case of conventional drilling the hole geometry differs from the ideal one if six-blade bits were used due to the influence of chamfers at the cutting edges and a non 180° plane end face and also in the case of a two-blade bit due to a non 180° plane end face and the tendency to more eccentric holes. Diamond bits cannot be recommended under all tested conditions due to their geometrical undefined shape.     

Experimental Evaluation of Residual Stresses in Pipes Manufactured by UOE and ERW Processes

Pipes are basic elements used in the construction of pipelines for the long-distance transportation of oil and gas and their derivatives. They can be manufactured by cold forming processes such as UOE and ERW, both widely used in the oil and gas industry. These processes produce high levels of non-uniform plastic deformation, which introduce a new state of residual stress into the material. In some cases, these stresses combine with mechanical stresses generated by external loads leading to service failures, interrupting the transmission line and increasing the risk of accidents. Therefore, determining in advance the residual stress distribution in pipes is an important task which involves the evaluation of the structural integrity. Six pipe samples obtained by the UOE and ERW processes were measured and evaluated using a portable optical device that combines radial in-plane digital speckle pattern interferometer (DSPI) with the incremental hole-drilling technique to measure residual stresses. The experimental results indicate a distinct residual stress distribution for each manufacturing process, while the measured residual stress distributions in the longitudinal and circumferential directions were similar at all measurement locations along an individual pipe.     

Residual Stress Measurements in Finite-Thickness Materials by Hole-Drilling

Hole-drilling measurements of residual stresses are traditionally made on materials that are either very thick or very thin compared with the hole diameter. The calibration constants needed to evaluate the local residual stresses from the measured strain data are well established for these two extreme cases. However, the calibration constants for a material with finite thickness between the extremes cannot be determined by simple interpolations because of the occurrence of local bending effects not present at either extreme. An analytical model is presented of the bending around a drilled hole in a finite thickness material and a practical procedure is proposed to evaluate the corresponding hole-drilling calibration constants.     

Elastoplastic analysis of nonlinearly hardening variable thickness annular disks under external pressure

Based on von Mises’ yield criterion, deformation theory of plasticity and Swift’s hardening law, elasto-plastic deformation of variable thickness annular disks subjected to external pressure is studied. A nonlinear shooting method using Newton’s iterations with numerically approximated tangent is designed for the solution of the problem. Considering a thickness profile in the form of a general parabolic function, the condition of occurrence of plastic deformation at the inner and outer edges of the annular disk is investigated. A critical disk profile is determined and the corresponding elastic–plastic stresses as well as the residual stress distribution upon removal of the applied pressure are computed and discussed.     

Determination of residual-stress variation with depth by the hole-drilling method

The hole-drilling method is a residual-stress measurement technique in which a blind hole (usually 1.6 mm or 3.2 mm in diameter) is drilled into a material and the strain perturbances around the hole are measured by surfacemounted strain gages. The conventional hole-drilling-method procedure is to analyze the net strain changes due to the drilling of the full-depth hole (usually about 100 percent of hole diameter) and to interpret the resulting stress calculations insofar as they represent the average stresses through the hole depth. It has been determined that this procedure may lead to significant errors, particularly where there are large stress variations through the hole depth. Such errors may be difficult to detect simply by observing the strain data. This paper describes a finite-element procedure which was used to develop calibration constants to allow measurements of residual-stress variation with depth to be routinely performed by the hole-drilling method.     

MEASUREMENT OF NON-UNIFORM RESIDUAL STRESSES BY COMBINED MOIRE INTERFEROMETRY AND HOLE-DRILLING METHOD： THEORY, EXPERIMENTAL METHOD AND APPLICATIONS

Hole-drilling method is one of the most convenient methods for engineering residual stress measurement. Combined with moiré interferometry to obtain the relaxed whole-field displacement data, hole-drilling technique can be used to solve non-uniform residual stress problems, both in-depth and in-plane. In this paper, the theory of moiré interferometry and incremental hole-drilling (MIIHD) for non-uniform residual stress measurement is introduced. Three dimensional finite element model is constructed by ABAQUS to obtain the coefficients for the residual stress calculation. An experimental system including real-time measurement, automatic data processing and residual stresses calculation is established. Two applications for non-uniform in-depth residual stress of surface nanocrystalline material and non-uniform in-plane residual stress of friction stir welding are presented. Experimental results show that MIIHD is effective for both non-uniform in-depth and in-plane residual stress measurements. The project supported by the FRAMATOME ANP     

Tikhonov regularization with Incremental Hole-Drilling and the Integral Method in Cross-Ply Composite Laminates

Background: Incremental hole-drilling with the integral method has been extensively used in composite laminates but is sensitive to small measurement errors. Error sensitivity can be reduced by limiting the number of depth increments used in the calculation procedure. This approach is limited if a rapidly varying residual stress distribution exists since the calculated stress in each incremental depth is considered constant. Distortion of stress results can consequently occur due to averaging effects if the depth increments become too large. Tikhonov regularization is usually applied in isotropic materials to smooth the resulting residual stress distribution and reduce stress uncertainties, but has only been applied to composite laminates using the slitting technique. Objective: The intention of this work is to extend the use of Tikhonov regularization to incremental hole-drilling of composite laminates using the integral method. Methods: Finite element modelling is used to calculate the necessary calibration coefficients for unit pulses of uniform stress. Monte Carlo simulation is used to the determine uncertainties in the calculated residual stress distributions. Tikhonov regularization is optimised to reduce the stress uncertainty, while ensuring that the stress solution is not distorted. Results: The method is demonstrated on a GFRP (Glass fibre reinforced plastic) laminate of [0₂/90₂]_s construction and the calculated residual stress field is compared with those obtained by the standard integral method and series expansion. Conclusions: It is found that Tikhonov regularization significantly improves the accuracy of the standard integral method in composite laminates and shows good agreement with the series expansion method.

     

Hole-Drilling Residual Stress Measurement with Artifact Correction Using Full-Field DIC

A full-field, multi-axial computation technique is described for determining residual stresses using the hole-drilling method with DIC. The computational method takes advantage of the large quantity of data available from full-field images to ameliorate the effect of modest deformation sensitivity of DIC measurements. It also provides uniform residual stress sensitivity in all in-plane directions and accounts for artifacts that commonly occur within experimental measurements. These artifacts include image shift, stretch and shear. The calculation method uses a large fraction of the pixels available within the measured images and requires minimal human guidance in its operation. The method is demonstrated using measurements where residual stresses are made on a microscopic scale with hole drilling done using a Focused Ion Beam – Scanning Electron Microscope (FIB-SEM). This is a very challenging application because SEM images are subject to fluctuations that can introduce large artifacts when using DIC. Several series of measurements are described to illustrate the operation and effectiveness of the proposed residual stress computation technique.     

Residual Stress Measurement in Composite Laminates Using Incremental Hole-Drilling with Power Series

Current methods for incremental hole-drilling in composite laminates have not been successfully applied in laminates of arbitrary construction or where significant variation of residual stress exists within a single ply. This work presents a method to overcome these limitations. Series expansion is applied to each ply orientation separately so that the discontinuities in the residual stresses at ply interfaces can be correctly captured. Temperature variations described by power series are used to set up eigenstrains and consequent stresses which vary in the through-thickness direction. The calibration coefficients at each incremental hole depth are calculated through the use of finite element modelling. The inverse solution employs a least-squares approach which makes the resulting solution insensitive to measurement uncertainty. Robust uncertainties in the residual stress distributions are determined using Monte Carlo simulation. The residual stress distribution is found from that combination of series orders in the different ply orientations that has the lowest RMS uncertainty, selected only from those combinations that have converged. The method is demonstrated on a GFRP laminate of [0₂/+45/?45]_s construction where it is found that transverse cracking of the plies at the inner surface of the hole may have impacted on the accuracy of the results.     

J-integral and crack driving force in elastic–plastic materials

This paper discusses the crack driving force in elastic–plastic materials, with particular emphasis on incremental plasticity. Using the configurational forces approach we identify a “plasticity influence term” that describes crack tip shielding or anti-shielding due to plastic deformation in the body. Standard constitutive models for finite strain as well as small strain incremental plasticity are used to obtain explicit expressions for the plasticity influence term in a two-dimensional setting. The total dissipation in the body is related to the near-tip and far-field J-integrals and the plasticity influence term. In the special case of deformation plasticity the plasticity influence term vanishes identically whereas for rigid plasticity and elastic-ideal plasticity the crack driving force vanishes. For steady state crack growth in incremental elastic–plastic materials, the plasticity influence term is equal to the negative of the plastic work per unit crack extension and the total dissipation in the body due to crack propagation and plastic deformation is determined by the far-field J-integral. For non-steady state crack growth, the plasticity influence term can be evaluated by post-processing after a conventional finite element stress analysis. Theory and computations are applied to a stationary crack in a C(T)-specimen to examine the effects of contained, uncontained and general yielding. A novel method is proposed for evaluating J-integrals under incremental plasticity conditions through the configurational body force. The incremental plasticity near-tip and far-field J-integrals are compared to conventional deformational plasticity and experimental J-integrals.     

Intralaboratory Repeatability of Residual Stress Determined by the Slitting Method

This paper presents repeated slitting method measurements of the residual stress versus depth profile through the thickness of identically prepared samples, which were made to assess repeatability of the method. Measurements were made in five 17.8 mm thick blocks cut from a single plate of 316L stainless steel which had been uniformly laser peened to induce a deep residual stress field. Typical slitting method techniques were employed with a single metallic foil strain gage on the back face of the coupon and incremental cutting by wire EDM. Measured residual stress profiles were analyzed to assess variability of residual stress as a function of depth from the surface. The average depth profile had a maximum magnitude of −668 MPa at the peened surface. The maximum variability also occurred at the surface and had a standard deviation of 15 MPa and an absolute maximum deviation of 26 MPa. Since measured residual stress exceeded yield strength of the untreated plate, microhardness versus depth profiling and elastic–plastic finite element analysis were combined to bound measurement error from inelastic deformation.     

The accuracy of residual stress measurement by the hole-drilling method

This paper describes the verification of the accuracy of residual stress measurement by the hole-drilling method. The strain measurement is simulated by the use of the indirect fictitious-boundary integral method. As an example, a finite rectangular plate subjected to initial stress is treated, and a simulated measurement of the residual stress is made using the strain relieved during hole drilling. The accuracy of residual stress measurement is estimated by comparing the simulated measured residual stress with the actual residual stress, i.e., the given initial stress. The results are shown for various distances and angles of strain gages. Also, the influences of the eccentricity of the hole from the center of the strain gages and the effect of a boundary near the hole are examined.     

Plastic buckling analysis of thick plates using p-Ritz method

This paper is concerned with the application of the p-Ritz method for the plastic buckling analysis of thick plates. In order to allow for the effect of transverse shear deformation in thick plates, the Mindlin plate theory is adopted. The plastic buckling behaviour of the plate is captured by using the incremental and deformation theories of plasticity. The material property of the plate is assumed to obey the Ramberg–Osgood stress–strain relation. The p-Ritz method will be applied to obtain the governing eigenvalue equation for the plastic buckling analysis of uniformly stressed plates with edges defined by polynomial functions. In the p-Ritz method, the displacement functions of the plate are approximately represented by the product of mathematically complete two-dimensional polynomial functions and boundary equations raised to appropriate powers that ensure the satisfaction of the geometric boundary conditions. The validity, convergence and accuracy of the method were demonstrated for various plate shapes such as rectangular, triangular and elliptical shapes. A parametric study was also undertaken to study the plastic buckling behaviour and the effect of transverse shear deformation.