Residual Stress Determination Using Cross-Slitting and Dual-Axis ESPI

Hole-drilling and Electronic Speckle Pattern Interferometry (ESPI) are used to measure residual stresses in metal specimens. The slitting method is chosen as an alternative to the more commonly used hole-drilling method because it involves less material removal and leaves large areas of highly deformed material available to be measured. However the conventional single-slitting method is sensitive only to the stress component perpendicular to the slit direction, and thus has a strong directional bias. Conventional ESPI has a similar bias because it responds to surface displacements in a specific sensitivity direction. In this paper, a novel cross-slitting method with dual-axis ESPI measurements is proposed to address both directional biases. Cross-slitting is introduced as a means of releasing all in-plane stress components. The dual-axis ESPI system uses diagonal-mirror and shutter devices to provide surface displacement measurements in orthogonal in-plane directions. The combination of the cross-slit and dual-axis measurement gives isotropic sensitivity to the in-plane residual stress components. Experimental measurements are described that illustrate the capability and effectiveness of the cross-slitting/ESPI technique.     

Comparison Between Surface and Near-Surface Residual Stress Measurement Techniques Using a Standard Four-Point-Bend Specimen

Background

Determination of near-surface residual stresses is challenging for the available measurement techniques due to their limitations. These are often either beyond reach or associated with significant uncertainties.

Objective

This study describes a critical comparison between three methods of surface and near-surface residual stress measurements, including x-ray diffraction (XRD) and two incremental central hole-drilling techniques one based on strain-gauge rosette and the other based on electronic speckle pattern interferometry (ESPI).

Methods

These measurements were performed on standard four-point-bend beams of steel loaded to known nominal stresses, according to the ASTM standard. These were to evaluate the sensitivity of different techniques to the variation in the nominal stress, and their associated uncertainties.

Results

The XRD data showed very good correlations with the surface nominal stress, and with superb repeatability and small uncertainties. The results of the ESPI based hole-drilling technique were also in a good agreement with the XRD data and the expected nominal stress. However, those obtained by the strain gauge rosette based hole-drilling technique were not matching well with the data obtained by the other techniques nor with the nominal stress. This was found to be due to the generation of extensive compressive residual stress during surface preparation for strain gauge installation.

Conclusion

The ESPI method is proven to be the most suitable hole-drilling technique for measuring near-surface residual stresses within distances close to the surface that are beyond the penetration depth of x-ray and below the resolution of the strain gauge rosette based hole-drilling method.

     

Full-Field High-Strain Gradient Evaluation from Wrapped ESPI Data Using Phasors

Electronic Speckle Pattern Interferometry (ESPI) is a sensitive optical method commonly used for making full-field measurements of surface displacements. It would be very desirable to be able to extend the technique also to determine surface strains. This would provide a full-field, non-contact strain measurement method that avoids the substantial installation burden of strain gauges. A mathematical approach is described where the ESPI data from an in-plane interferometer are numerically differentiated to determine surface strains. This is a challenging process because numerical differentiation is very sensitive to the presence of noise and ESPI data are inherently noisy. In addition, the phase information from ESPI data are wrapped modulo-2π. The resulting phase discontinuities make it difficult to use local averaging to smooth the data. A technique is described here where phasors are used to avoid the need for phase unwrapping. The effect of noise is reduced by a localized multiple smoothing technique that is effective in preserving spatial resolution, even near very high strain concentrations. Example measurements are shown and the effectiveness of the proposed method is illustrated.     

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.     

采用电子散斑干涉法对车灯配光镜内部缺陷问题的研究

在汽车车灯配光镜的生产过程中，由于用热压工艺而产生的热应力无法完全释放，积聚在其内部，产生不可见的细微缺陷。这些缺陷在一定的外界条件下扩展、生长，导致表面开裂、破碎，造成产品的报废。目前通常采用的有损检测方法虽然能够检测出缺陷的存在，但也破坏了车灯。为此，本文用采用电子散斑干涉法(ESPI)对车灯配光镜表面由于热应力而造成的变形以及细微裂纹缺陷的无损检测进行了实验研究，量化得到了配光镜表面在热载荷作用下的连续热变形分布。实验表明，用ESPI在热载荷的方式下可以成功地测量出配光镜缺陷的存在，并通过进一步研究，对同一型号但在残余应力分布上存在微小差异的两个车灯，我们给出了判别它们的定量标准。     

DIC-Based Surface Motion Correction for ESPI Measurements

Electronic Speckle Pattern Interferometry (ESPI) provides a sensitive technique for measuring surface deformations. The technique involves comparison of the speckle phase angles within surface images measured before and after material deformation. This phase angle comparison requires that the speckle positions be consistent in all images. A lateral shift between image sets of just one pixel substantially degrades ESPI measurements, while a shift of two or more pixels typically causes complete decorrelation and compromises the measurement entirely. To prevent such rigid body motions, the specimen and the optical system must be rigidly fixed. This requirement typically impedes use of the ESPI method in applications outside laboratories or where it is necessary to remove the specimen from the optical setup between ESPI measurements. Here, Digital Image Correlation (DIC) is used to track speckle motion caused by specimen displacement between ESPI phase stepped image sets. The measured image set can then be mathematically shifted to restore the original speckle locations, thereby recorrelating the ESPI measurement. Examples are presented where ESPI measurements are successfully made with specimen shifts over 60 pixels.     

Simultaneous Measurement of Plate Natural Frequencies and Vibration Mode Shapes Using ESPI

The natural frequencies and vibration mode shapes of flat plates are simultaneously measured using ESPI. The method involves measuring the surface shape of a vibrating plate at high frame rate using a modified Michelson interferometer and high-speed camera. The vibration is excited here by impact; white (random) noise could alternatively be used. Fourier analysis of the acquired data gives the natural frequencies and associated mode shapes. The analytical procedure used has the advantage that it simultaneously identifies full-field quantitative images of all vibration modes with frequencies up to half the sampling frequency. In comparison, the ESPI time-averaging and the traditional Chladni methods both require that the plate be excited at each natural frequency to allow separate qualitative measurements of the associated mode shapes. The Instrumented Hammer method and Laser Doppler Vibrometry give quantitative measurements but require sequential sampling of individual points on the test surface to provide full-field results. Example ESPI measurements are presented to illustrate the use and capabilities of the proposed plate natural frequency and mode shape measurement method.     

集中力作用下铝合金材料内部柱状缺陷检测的研究

工程中,构件的内部会因为各种原因不可避免地存在各种损伤或缺陷。本文通过弹性力学理论给出含柱状缺陷的铝合金材料在受到集中力作用下的离面位移场。同时运用电子散斑干涉方法成功地测量出试件缺陷覆盖层在受到集中力情况下的离面位移。理论和实验结果对比表明,利用电子散斑干涉术技术能够精确地测量含缺陷材料表面的离面位移。此实验方法可以作为一种新型的探测物体内部缺陷所处的位置和大小的评估办法。     

Residual Stress Determination Using Hole Drilling and 3D Image Correlation

In recent years, the hole drilling method for determining residual stresses has been implemented with optical methods such as holographic interferometry and ESPI to overcome certain limitations of the strain rosette version of hole drilling. Although offering advantages, the interferometric methods require vibration isolation, a significant drawback to their use outside of the laboratory. In this study, a 3D image correlation approach was used to measure micron-sized surface displacements caused by the localized stress relief associated with hole drilling. Residual stresses were then found from the displacements using non-dimensional relations previously derived by finite element analysis. A major advantage of image correlation is that it does not require interferometric vibration isolation. Experiments were performed to check the ability of this new approach for uniaxial and equi-biaxial states of stress. Stresses determined by the approach were in good agreement with computed values and those determined by hole drilling using holographic interferometry.     

光测条纹图处理中免除噪声的正则化条纹法

在光测条纹图自动处理研究领域内有许多不同种类的处理方法,免除噪声的正则化条纹法,或称纯条纹灰度法,是有效的方法之一。本文综述了作者提出的免除噪声正则化条纹法的原理和多种方法。然后对广义旋滤波进行了改进,用于消除 Ｅ Ｓ Ｐ Ｉ图的散斑噪声,并且不损害条纹信号分布。实验表明本方法具有良好的结果和前景。     

ESPI技术对外贴纤维混凝土加固承载的实验研究

采用电子散斑干涉技术,对外贴碳纤维加固混凝土梁的外贴材料位移的分布特征,进行了全场实时测量,通过实验获得的散斑干涉条纹图可以得到外贴材料与混凝土梁的粘结传力长度随粘结长度及初始载荷之间的关系;了解用于加固的碳纤维材料的应变分布特点和产生梁侧剥离破坏时的碳纤维表面位移(应变)的演化过程。实验还说明了电子散斑干涉技术不仅可用于位移的测量,而且也可用于结构安全监测和破坏预报。文中给出了对C20D、C25A和C60C侧贴碳纤维板加固在不同载荷作用直到构件破坏前的位移测试及对试件C60C轴线上的剪应力分析结果。     

Incremental Hole Drilling for Residual Stress Analysis of Thin Walled Components with Regard to Plasticity Effects

The incremental hole-drilling method is widely used in residual stress depth distribution analysis. However, two specific difficulties with the generalization of the incremental method exist, including the consideration of the sample thickness and residual stress states close to the local material’s yield strength. The stress concentration effect of the hole can lead to plastic deformation in the vicinity of the hole, which results in an overestimation of residual stresses. Typically, the effect of the component’s thickness and the plasticity effects are analyzed separately and correction approaches are proposed. In the current paper, we analyze the combined effects of plasticity and thickness on residual stress analysis using the incremental hole-drilling method. A systematic study was performed on steel samples with (i) isotropic and (ii) anisotropic elastic and elasto-plastic material behavior with varying thicknesses ranging between 1 mm and 4 mm. Electronic speckle pattern interferometry (ESPI) hole-drilling experiments were conducted on beam samples loaded using a 4-point bending fixture. Finite element simulations were conducted to gain insight into the effects of incremental hole-drilling. The results indicate that reducing the component’s thickness increases the plastic deformation in the vicinity of the hole and results in significant stress deviations. Thin components bend during hole-drilling as a result of the loss of stiffness, which amplifies the plasticity effect.     

Whole-field strain measurement in a pin-loaded plate by electronic speckle pattern interferometry and the finite element method

The strain field in an epoxy plate loaded in tension through a steel pin is determined using electronic speckle pattern interferometry (ESPI) and the finite element method (FEM). In a dual-beam illumination speckle interferometer, the in-plane component of the displacement at the plate's surface is accurately measured using a four-step phase-shifting algorithm. Digital image processing algorithms have been developed for noise reduction and strain calculation directly in the computer from the phase map with a strain gage length of about 0.4 mm. A whole-field strain map is obtained, as well as distributions of strain concentration factor, in critical regions near the hole of the plate. FEM is used to perform a nonlinear contact analysis accounting for friction effects at the pin/hole interface. The agreement between experimental results and numerical predictions is good. In terms of speed, accuracy and ease of use, dual-beam ESPI appears to be a superior method of whole-field strain analysis.     

干涉条纹图处理的等值线窗口滤波和摄像测量在国防试验的应用

对图像进行滤波或称平滑是干涉条纹图像处理中的一项重要工作。一幅未经处理的原始图像或多或少存在着不同程度的噪声干扰,特别是散斑和Insar干涉条纹图,信噪比很低,难以处理。本文针对光测力学中光学干涉方法得到的条纹图,提出了一种新的滤波方法条纹等值线窗口滤波,并对这种滤波方法进行了研究讨论,提出了几种确定等值线窗口的不同方法。这种滤波方法根据干涉条纹图不同断面上灰度分布的不同特点,选择沿条纹走向的条纹等值线窗口进行滤波,在最大消除条纹图噪声的同时,也能保证对条纹损伤最小。摄像测量技术正在迅速发展和得到广泛应用,在国防试验和航天飞行任务中发挥着不可替代的作用。本文也介绍了作者近年来在该领域所做的应用研究,包括在火箭、导弹发射试验,冲击、碰撞等过程中的动态目标运动测量;针对航天航空和力学工程领域的视频图像实时分析;飞行器三维运动测量;基于投影条纹的物体三维形貌精密测量方法研究;以及对接航天器位置和姿态的实时测量。在这些应用中都实现了高精度测量。     

电子剪切散斑在检测材料缺陷中的应用

随着电子技术、计算机技术的飞速发展,传统的全息干涉技术已经发展到了电子散斑和电子剪切散斑阶段。电子散斑和电子剪切散斑不仅可以完成表面变形量的测量,并且由于它们具有实时性、高灵敏度、非接触性和全场测量等优点,在工业和科研领域中得到了越来越广泛的应用。本文首先介绍了电子剪切散斑干涉的基本原理,然后着重介绍了自行编制的对离面位移的电子剪切散斑图像进行处理的系统。该图像处理系统的主要功能有平滑、区域标记、像素统计等。用该系统对图像进行处理后,可以直接得到缺陷的实际大小。通过对带有已知缺陷模型的实际测量,所得结果与实际吻合较好,说明该图像处理系统是可行的。     

Two-dimensional electronic-speckle-pattern interferometry and concrete-fracture processes

Electronic-speckle-pattern interferometry (ESPI) is an optical nondestructive testing technique. A two-dimensional in-plane displacement sensitive interferometer was designed to observe progressive development of microcracking of carbon-fiber-reinforced concrete specimens subjected to tension. By using the two-dimensional ESPI system, the fracture processes, crack initiation and crack propagation of concrete specimens were monitored qualitatively and in real time. The displacement and strain fields were analyzed quantitatively by using digital image processing techniques. Paper was presented at the 1993 SEM Spring Conference on Experimental Mechanics held in Dearborn, MI on June 9–11.     

Partial polar decomposition inverse method applied to determination of internal stresses in an elastic complex structure

An inverse method is developed to evaluate a distribution of internal-stress tractions on an internal surface of an elastic complex structure. The traction distribution is evaluated by measuring a remote displacement field generated when the surface of interest is sectioned. This formulation employs partial polar decomposition (PPD) of a rectangular matrix within the global finite element stiffness matrix for the process of inversion. A systematic regularization process is also provided for the PPD inverse method. This method avoids cumbersome rigid body displacement control required in the formalism of compliance matrix inversion. The method is robust in measuring residual stresses in an elastic complex structure, in particular, multiply connected regions. The inversion method has been tested experimentally by using electronic speckle pattern interferometry (ESPI) with a specimen of multiply connected regions. Experimental results show that the regularized solution using partial polar decomposition converges quickly with a small number of series terms.     

热毛细对流温度场ESPI检测研究

在地面上用二维液体盒研究了热壁下气泡周围液体中的热毛细对流现象,并应用电子散斑干涉技术（ESP）对热毛细对流温度场进行了实时检测研究,给出了部分典型的实验结果。     

电子散斑和全息光弹法相结合测量透明材料的应力强度因子K1

全息光弹性中等和线是获得断裂力学中应力强度因子的一种有效方法之一。但用传统的全息光弹性方法获取等和线需暗房，要经过显影定影及再现，而且不能直接数字化使其应用受到限制。本文提出一种将全息光弹性与相移电子散斑干涉（Electric Speckle Pattern Interferometry，简称ESPI）有机结合的方法，不但克服传统全息光弹性的不足，而且使全息光弹性实现了数字化。文中将这一方法成功应用于有预制裂纹的三点弯曲试件上，定量求得其应力强度因子（Stress Intensity Factor，简称SIF）K1，而且实验值和理论值具有相一致的结果。     

Two-Dimensional Mapping of In-plane Residual Stress with Slitting

This paper describes the use of slitting to form a two-dimensional spatial map of one component of residual stress in the plane of a two-dimensional body. Slitting is a residual stress measurement technique that incrementally cuts a thin slit along a plane across a body, while measuring strain at a remote location as a function of slit depth. Data reduction, based on elastic deformation, provides the residual stress component normal to the plane as a function of position along the slit depth. While a single slitting measurement provides residual stress along a single plane, the new work postulates that multiple measurements on adjacent planes can form a two-dimensional spatial map of residual stress. The paper uses numerical simulations to develop knowledge of two fundamental problems regarding two-dimensional mapping with slitting. The first fundamental problem is to estimate the quality of a slitting measurement, relative to the proximity of a given measurement plane to a free surface, whether that surface is the edge of the original part or a free surface created by a prior measurement. The second fundamental problem is to quantify the effects of a prior slitting measurement on a subsequent measurement, which is affected by the physical separation of the measurement planes. The results of the numerical simulations lead to a recommended measurement design for mapping residual stress. Finally, the numerical work and recommended measurement strategy are validated with physical experiments using thin aluminum slices containing residual stress induced by quenching. The physical experiments show that two-dimensional residual stress mapping with slitting, under good experimental conditions (simple sample geometry and low modulus material), has precision on the order of 10 MPa. Additional validation measurements, performed with x-ray diffraction and ESPI hole drilling, are within 10 to 20 MPa of the results from slitting.