Modifications to the hole-drilling technique of measuring residual stresses for improved accuracy and reproducibility

The hole-drilling technique is a relatively well established and straightforward semidestructive method for measuring residual stresses in fabricated components. However, a number of factors can have a marked influence on the accuracy of this technique. Some of the factors evaluated in the present work were the method of drilling the hole, the size and shape of the hole, and the equations used to calculate the principal residual stresses from the relaxed-strain measurements. In this investigation, air-abrasive hole drilling using a 0.062-in.-ID stationary nozzle gave the most reproducible and accurate results. Of the three approaches used to calculate the residual stresses, one method proved to be superior, especially in a biaxial-stress field.     

Hole-drilling strain-gage method of measuring residual stresses

The hole-drilling strain-gage method of measuring residual stresses in elastic materials can be termed semidestructive if holes of very small diameters are used. The method permits the magnitudes and principal directions of residual stresses at the hole location to be determined. This is accomplished by means of an emirpically determined relation between the magnitudes and directions of the principal stresses and the strain relaxation about the hole as the hole is drilled. This relation was obtained for a nondimensional model of the hole-gage assembly in order to make the results independent of hole size. A generalization was postulated to extend the use of this calibrated solution to the measurement of residual stresses in all elastic, isotropic materials.I. Vigness was HeadPaper was presented at 1966 SESA Spring Meeting held in Detroit, Mich. on May 4–6.     

An investigation of the hole-drilling technique for measuring planar residual stress in rectangularly orthotropic materials

The applicability of the semidestructive holedrilling technique to the experimental determination of residual stresses in relatively thin rectangularly orthotropic materials was investigated. From the exploratory work, it was determined that the similitudes, for measurements at a particular ratio of hole depth to diameter, which exist for thick materials are not present in relatively thin materials. This implies that calibration tests must be made for each combination of strain-gage size and plate thickness. As a consolation, however, it was found that there is no need to drill to an optimum depth for thin materials. That is, one may simply drill a small hole completely through the material to obtain the desired strain change.     

Optimal calculation steps for the evaluation of residual stress by the incremental hole-drilling method

The integral method is a suitable calculation procedure for the determination of nonuniform residual stresses by semidestructive mechanical methods such as the hole-drilling method and the ring-core method. However, the high sensitivity to strain measurement errors due to the ill conditioning of the equations has hindered its practical use. the analysis of the influence of the strain measurment error on the computed stresses carried out in the present work has showed that, given both maximum hole depth and number of total steps, the error sensitivity depends on the particular depth increment distribution used. By means of the matrix formulation, the depth increment distribution that optimizes the numerical conditioning is investigated. Numerical simulations and an experimental test have corroborated the best performance of the proposed step distribution with respect to the constant or increasing distributions commonly used.     

Multiple trenching: a simple self-calibrating method of residual-stress measurement

A simple semidestructive residual-stress-measurement technique, particularly suitable for measurement parallel to edges or on outside radii of components, is presented. The nature of the technique obviates reliance upon calibration constants such as have been obtained for the hole-drilling and ring-cutting methods for residual-stress measurement. Use of such calibration constants might seriously underestimate stress values for relatively shallow surface stresses such as may be produced by, for example, grinding or thermochemical treatment.     

应用固有应变理论计测对接焊钢管残余应力场的实验研究

本文采用改进后的固有应变法对对接焊管接头残余应力计测进行了理论分析,确定了测量方案,研究果结表明对于可处理成轴对称问题的对接焊管残余应力问题只需不太多的测量值就能获得残余应力全场。本文就一个对接焊钢管试件进行了实验,实验计测结果同其它文献较为一致。它显示了应用改进后的固有应变理论决定对接焊钢管残余场的有效性。     

Measurement of Applied Stresses and Residual Stresses on a Residual Stress Model by Applying Two Different Loads

Applied stresses on a residual stress model have previously been obtained by measuring the residual stresses and the resultant stresses generated by applying a load. The present paper reports that the applied stresses and the residual stresses on the residual stress model can be obtained by measuring two resultant stresses generated by applying loads of two different magnitudes. In the proposed method, the residual stresses need not be obtained from the residual stress model before applying a load. The residual stress model used to test the proposed method is a circular disk with frozen stresses that is subjected to a diametral compressive load at a certain angle. The applied stresses and the residual stresses on a residual stress model were experimentally and precisely obtained by digital photoelasticity using linearly polarized light.     

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.     

Ultrasonic Measurements of Residual Stresses Caused by Severe Thermomechanical Deformation during FSW

In engineering processes, residual stresses can be intense once high plastic deformation and temperature gradient are involved. This is exactly the case for friction stir welding (FSW) in which both rotational and translational movements of the tool induce extreme temperature gradient and plastic deformation. In this research, the extents of longitudinal and transverse residual stresses are measured within the AA7075-T6 plates welded through FSW process using ultrasonic method. According to the obtained results, it can be found that the residual stress is of the tensile type adjacent to the welding line whereas it is of the compressive type far from the welding line. Another observation is that the longitudinal residual stresses are considerably greater than the transverse residual stresses. Furthermore, with the aim of investigating the effects of rotation and traverse velocities of the tool on residual stress, experiments are carried out at three different rotation and traverse velocities. Based on the acquired results, it is observed that upon increasing the rotation and traverse velocities, the longitudinal and transverse residual stresses decrease and increase, respectively.     

A Dynamic Method for the Residual Stress Measurement During Polymer Crystallization

A new dynamic method based on bilayer system is proposed to characterize the residual stress formation during the crystallization of semi-crystalline polyethylene glycol 10000 (PEG10000). The resin is coated on a solid polymeric film to create a filmsubstrate compound. Its temperature field and dynamic deflection are monitored by synchronized optical and thermography cameras. The crystallization kinetics is first characterized from the former information. Then a simple dynamic model is proposed to relate the dynamic deflection with crystallization process. Residual stresses are established and in the range of 0–2.1 MPa. The generation of residual stresses is due to the edge constraints of the cantilever beam and to the increase of viscosity during solidification that allows the polymer to carry tensile loadings. The spherulite impingement is found to be important for this period from a microscopic view. Boundary condition should be well controlled to steer residual stresses. Such method is promising to measure residual stresses at the micro-scale for polymers to be spread on a flexible substrate and can mimic different mechanical situations of interest.     

A Novel Cutting Strategy for Measuring Two Components of Residual Stresses Using Slitting Method

An exact knowledge of residual stresses that exist within the engineering components is essential to maintain the structural integrity. All mechanical strain relief (MSR) techniques to measure residual stresses rely on removing a section of material that contains residual stresses. Therefore, these techniques are destructive as the integrity of the components is compromised. In slitting method, as a MSR technique, a slot with an increasing depth is introduced to the part incrementally that results in deformations. By measuring these deformations the residual stress component normal to the cut can be determined. Two orthogonal components of residual stresses were measured using the slitting method both experimentally and numerically. Different levels of residual stresses were induced into beam shaped specimens using quenching process at different temperatures. The experimental results were then compared with those numerically predicted. It was shown that while the first component of residual stress was being measured, its effect on the second direction that was normal to the first cut was inevitable. Finally, a new cutting configuration was proposed in which two components of residual stresses were measured simultaneously. The results of the proposed method indicated a good agreement with the conventional slitting.     

Measurement of residual stress in the weld overlay piping components

In general industry, especially in the nuclear industry, welding overlay repair is an important repair method mainly used to rebuild piping systems suffering from intergranular stress-corrosion cracking (IGSCC).The pipe surface is mechanically ground to obtain a smooth surface after the welding overlay repair. A better understanding of the effect of repair and grinding processes on the residual stresses at the surface of weld overlay is required. To obtain this understanding, it is necessary to measure directly the distribution of residual stresses on the specimen. It is expected that compressive residual stress should be induced at the inner wall surface of the pipe for prevention of IGSCC.The performance evaluation of welding overlay repair relies on whether or not the level and characteristic of the residual stress can be measured accurately. In this study, the hole-drilling strain-gage method, using the incremental drilling technique, was adopted to estimate the residual stresses on the inner and outer walls of the weld overlay pipe. The experimental results indicate that the residual stress at the pipe inner surface is compressive while that of the outer surface is tensile. Also, it is found that the depth affected by grinding is about 1.016 mm.     

Improvement of the Contour Method for Measurement of Near-Surface Residual Stresses from Laser Peening

A study was conducted to develop a methodology to obtain near-surface residual stresses for laser-peened aluminium alloy samples using the contour method. After cutting trials to determine the optimal cut parameters, surface contours were obtained and a new data analysis method based on spline smoothing was applied. A new criterion for determining the optimal smoothing parameters is introduced. Near-surface residual stresses obtained from the contour method were compared with X-ray diffraction and incremental hole drilling results. It is concluded that with optimal cutting parameters and data analysis, reliable near-surface residual stresses can be obtained by the contour method.     

Residual stresses in squeeze-cast aluminum rods

The longitudinal slitting technique has been applied to determining and comparing the residual stresses in as-cast and squeeze-cast aluminum rods. Residual stresses in the squeeze-cast aluminum alloy rods are found to increase with applied punch pressures under a constant die-base thermocouple reference temperature. For the variations of residual stresses with varying die-base thermocouple reference temperatures, a peak residual stress is found to occur at a die-base thermocouple reference temperature of 100° C. A semi-empirical formula is derived for the determination of the maximum longitudinal residual stress in the tapered cylindrical as-cast aluminum alloy, from which the maximum longitudinal residual stresses for squeeze cast can be determined, using the residual-stress ratios obtained experimentally     

Residual-stress determination by single-axis holographic interferometry and hole drilling—Part I: Theory

A method is described for the rapid, accurate determination of residual stresses from a holographic interference fringe pattern. The pattern is generated by the displacement field caused by localized relief of residual stresses via the introduction of a small, shallow hole into the surface of a component or test specimen. The theoretical development of the holographic method is summarized. An example is given showing how the method can be applied to a typical experimentally observed fringe pattern to determine principal residual stresses and directions.     

X射线法测试1500m^3乙烯球罐焊接残余应力的现场应用

本文应用Ｘ射线应力仪对ＣＦ－６２钢制乙烯球罐焊接残余应力进行了现场测量，解决了大型球罐的残余应力现场测试过程中的技术问题，结果表明焊后残余应力水平较高而热处理效果良好     

Residual stresses in thin film systems: Effects of lattice mismatch,thermal mismatch and interface dislocations

This paper explores the mechanisms of the residual stress generation in thin film systems with large lattice mismatch strain, aiming to underpin the key mechanism for the observed variation of residual stress with the film thickness. Thermal mismatch, lattice mismatch and interface misfit dislocations caused by the disparity of the material layers were investigated in detail. The study revealed that the thickness-dependence of the residual stresses found in experiments cannot be elucidated by thermal mismatch, lattice mismatch, or their coupled effect. Instead, the interface misfit dislocations play the key role, leading to the variation of residual stresses in the films of thickness ranging from 100 nm to 500 nm. The agreement between the theoretical analysis and experimental results indicates that the effect of misfit dislocation is far-reaching and that the elastic analysis of dislocation, resolved by the finite element method, is sensible in predicting the residual stress distribution. It was quantitatively confirmed that dislocation density has a significant effect on the overall film stresses, but dislocation distribution has a negligible influence. Since the lattice mismatch strain varies with temperature, it was finally confirmed that the critical dislocation density that leads to the measured residual stress variation with film thickness should be determined from the lattice mismatch strain at the deposition temperature.     

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.     

Measuring Inaccessible Residual Stresses Using Multiple Methods and Superposition

The traditional contour method maps a single component of residual stress by cutting a body carefully in two and measuring the contour of the cut surface. The cut also exposes previously inaccessible regions of the body to residual stress measurement using a variety of other techniques, but the stresses have been changed by the relaxation after cutting. In this paper, it is shown that superposition of stresses measured post-cutting with results from the contour method analysis can determine the original (pre-cut) residual stresses. The general superposition theory using Bueckner’s principle is developed and limitations are discussed. The procedure is experimentally demonstrated by determining the triaxial residual stress state on a cross section plane. The 2024-T351 aluminum alloy test specimen was a disk plastically indented to produce multiaxial residual stresses. After cutting the disk in half, the stresses on the cut surface of one half were determined with X-ray diffraction and with hole drilling on the other half. To determine the original residual stresses, the measured surface stresses were superimposed with the change stress calculated by the contour method. Within uncertainty, the results agreed with neutron diffraction measurements taken on an uncut disk.     

Method of calculating residual stresses in semicircular notches in a surface hardened hollow cylindrical specimen

A method is proposed to study the distribution of residual stresses in a semicircular notch in a hollow cylindrical specimen after advanced surface plastic deformation. The initial information used in the method is one or two experimentally determined components of the residual stress tensor in the hardened layer of the smooth specimen. The problem is solved using a finite element technique taking into account initial plastic strains, which are set in correspondence to the residual stresses according to the laws of elasticity. The effect of the hardening technology and notch depth on the distribution of residual stresses is studied. Experimental verification of the method showed that the calculated and experimental data on the stress distribution over the depth of the layer are in good agreement.