A Comparison of Residual-stress Measurements Using Blind-hole, Abrasive-jet and Trepan-ring Methods

This article describes the results of residual-stress measurements which were made on an artillery-projectile metal part to determine whether the state of the stress could be a factor in promoting a failure that had occurred during ballistic test firing. An additional objective of the work was to evaluate the suitability of several different methods for measuring residual stresses by the performance of these measurements on the same metal part.     

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.     

Nondestructive residual-stress measurement on the inside surface of stainless-steel pipe weldments

The instrumentation, technique, and procedures are described for the nondestructive measurement of residual stresses on the inside surface of pipe as small as 10 in. in diam. The instrument is based upon a unique position-sensitive scintillation X-ray detector which provides for the most compact X-ray stress-measurement instrument available since the introduction of film cameras four decades ago. This instrument is capable of applying the single-exposure technique of X-ray stress measurements which results in unprecedented rapidity of stress measurement consistent with excellent precision and accuracy. The results of testing the precision and accuracy of the instrument on a zero-stress powder and four-point-bend specimen are given. Residual stresses in four austenitic stainless-steel girth-welded pipes are presented illustrating the effects of the different welding procedures. The results from the pipes confirm the beneficial residual-stress condition of heat-sink-welding procedures.     

On residual-stress measurements in light truck wheels using the hole-drilling method

An investigation of the effect of drilling speed, milling-cutter wear, drilling mode, and applied drilling force on residual-stress measurements in a light truck wheel using a milling guide manufactured by Measurements Group, Inc. is described. The milling variables chosen were used to minimize the residual stresses induced by the introduction of a hole into the wheel material. An improved hole-drilling procedure was developed and found to be successful in the residual-stress measurements for a light truck wheel.     

Residual stresses in thick electrodeposits of a nickel-cobalt alloy

Some electroplated metals contain residual stresses which can cause warpage or premature failure of parts plated or electrofomed with these materials. Noticeably absent from the literature are residual-stress data for finished parts. Typically for plated or electroformed parts, residual stresses are determined independently on thin strips and then piece parts are plated. This research describes a technique which can be used to measure stress on finished parts. The method involves drilling a hole in the part and measuring the resulting change of strain in the vicinity of the hole. Viability of this technique was demonstrated by measuring the stress in a nickel-cobalt deposit plated on an aluminum cylinder. Two separate runs, one 50 deg removed from the other, provided almost identical results; stress was 160 MN/m² (23,200 psi). Two other runs in a region where plating was somewhat thinner provided slightly lower results probably because all boundary-condition requirements were not met. The computed residual-stress values compared quite favorably with independent rigid-strip measurements of 131 MN/m² (19,000 psi) obtained for the solution before and after plating of the cylinder.     

Nonuniform residual-stress measurement by hole-drilling method

Considering the general stress field as the summation of two terms of a power series, a method for the measurement of nonuniform stress fields in thin plates by the hole-drilling method has been devised. The relieved-strain equations for the uniform and linear terms of the assumed power series have been calculated and the related constants of these equations for a range of hole diameter have been plotted.From the relieved-strain equations, it is shown that for a linear approximation of a field, a rosette gage with at least five grid elements is needed. A special rosette is proposed for the linear approximation of the residual-stress fields. In addition the equations used to determine the uniform parts, the direction, and the slopes are given. An example of the linear approximation is presented. It is shown that for some residual-stress fields, the conventional equations based on a uniform stress field produce erroneous results. The improved equations, however, provide the correct solution.     

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.     

Nondestructive residual-stress measurement in a wide-flanged rolled beam by acoustoelasticity

X-ray stress analysis is a standard nondestructive stress-measurement technique, but its use is limited in the sense that only a surface layer is surveyed. Recently, acoustoelasticity has emerged as a technique for nondestructive stress analysis. Acoustoelasticity makes use of stress-induced acoustic-birefringent effects. It gives stress distributions averaged through the thickness of a specimen. This technique is attractive because it does not require a transparent plastic model as photoelasticity does. However, much should be done before this method is established as a standard nondestructive technique of stress analysis. The most important among them is to separate stress-induced birefringence from that introduced by texture structure. For special cases, such as axisymmetric stress distributions and when a stress-free region is knowna priori, residual-stress distributions can be evaluated nondestructively. In this paper, we measured residual-stress distribution in a wide-flanged rolled beam by using a recently developed T-type transducer. The results were compared to those obtained from conventional destructive methods.     

Residual stresses in thick-walled cylinders resulting from mechanically induced overstrain

Autofrettage is a process for inducing elastic response in thick-walled cylinders subjected to internal pressures which otherwise cause plastic strains. To extend the use of autofrettage to higher pressure applications and to elminate many of the problems encountered in the use of the conventional process based on the use of direct internal hydrostatic pressure, a new technique has been developed which utilizes the mechanical advantage of a sliding wedge to produce the desired bore enlargement. Since the use of a sliding wedge or mandrel will induce shearing forces at the mandrel-cylinder interface, the resultant residual-stress distribution will differ from that theoretically predicted as characteristic of the direct hydrostatic process. It is the purpose of this work to determine the residual-stress distribution as a function of magnitude of overstrain and diameter ratio, and how it affects the reyielding characteristics of cylinders autofrettaged by this technique. Residual-stress distributions, determined by the Sachs boring-out technique for diameter ratios ranging from 1.5 to 2.3 and for several different magnitudes of overstrain, are shown. The shearing force associated with this technique induces substantial longitudinal residual stresses. The increase in the magnitude of this longitudinal residual stress with overstrain and the resultant decrease in the tangential residual stress are shown and discussed. Hydrostatic reyielding tests of autofrettaged cylinders are used to substantiate the decrease of tangential residual stress with increased overstrain. The substantially lower optimum overstrain as compared to the direct hydrostatic technique is shown and discussed. For optimum overstrain, the elastic strength of cylinders autofrettaged by swaging is comparable to that characteristic of the conventional process.     

Residual stresses in reverse-bend test samples for stress-corrosion testing

Cracking of Inconel Alloy 600 (registered trademark) u-bend tubes used in pressure-water-reactor (PWR) steam generators has been a major concern in the nuclear-power industry over the past several years. The mechanism of cracking has been determined to be intergranular stress-corrosion cracking with residual stresses a major contributor. A simple specimen known as a reverse u-bend (RUB) has been used by a number of laboratories to simulate the high stresses and plastic strain extant in the most susceptible regions of the u-bend tubes. This paper presents the results of residual-stress measurements on four RUB samples, each from a different laboratory.The results indicate that the individual RUB fabrication procedures used by different laboratories tend to produce different residual-stress patterns in the highly strained regions over 700 tensile to nearly 700-MPa compressive on different samples. Stress gradients on the order of 140 MPa/mm were found on some samples. The residual-stress patterns were seen to qualitatively predict the stress-corrosion-cracking pattern experienced on similar samples.Electric Power Research Institute.     

Measurement of Torsionally Induced Shear Stresses in Shrink-Fit Assemblies

Shear stresses along the shaft/hub interface in shrink-fit components, generated by torsional loads, can drive premature failure through fretting mechanisms. It is difficult to numerically predict these shear stresses, and the associated circumferential slip along the shaft/hub interface, due to uncertainties in frictional behaviour and the presence of steep stress gradients which can cause meshing problems. This paper attempts to provide validation of a numerical modelling methodology, based on finite element analysis, so the procedure may be used with confidence in fitness-for-purpose cases. Very few experimental techniques offer the potential to make measurements of stress and residual stress interior to metallic components. Even fewer techniques provide the possibility of measuring shear stresses. This paper reports the results of neutron diffraction measurements of shear stress and residual shear stress in a bespoke test specimen containing a shrink-fit. One set of measurements was made with a torsional load ‘locked-in’. A second set of measurements was made to determine the residual shear stress when the torsional load had been applied and removed. Overall, measurement results were consistent with numerical models, but the necessity for a small test specimen to allow penetration of the neutron beam to the measurement locations meant the magnitude of shear stresses was at the limits of what could be measured experimentally.     

Moiré interferometry determination of residual stresses in the presence of gradients

The full-field technique of high-sensitivity moiré interferometry in conjunction with a multiple-hole-drilling procedure is applied to residual-stress measurements in the presence of gradients. The method arrives at residual-stress estimates starting from in-plane displacement components. Successful applications of the method to problems simulating the nonuniform transverse residual stresses of welded joints are reported.Paper was presented at the 1990 SEM Spring Conference on Experimental Mechanics held in Albuquerque, NM on June 3–6.     

Brief investigation of induced drilling stresses in the center-hole method of residual-stress measurement

Results of experiments to measure induced drilling stresses in the center-hole method of residual-stress measurement are described. Five specimens of different metals were specially prepared in an attempt to relieve malerial residual stress. Surface-residual-stress measurements were then performed by the center-hole method with a conventionally used (low-speed) end mill and an ultra-high-speed drill. For each specimen, the relieved strains due to the hole drilling were significantly higher for the low-speed end mill than for the ultra-high-speed drill. Preliminary conclusions are that the ultra-high-speed drill would be much superior to the conventional low-speed end mill in the measurement of residual stress by the center-hole method.     

Measuring Multiple Residual-Stress Components using the Contour Method and Multiple Cuts

The conventional contour method determines one component of residual stress over the cross section of a part. The part is cut into two, the contour (topographic shape) of the exposed surface is measured, and Bueckner’s superposition principle is analytically applied to calculate stresses. In this paper, the contour method is extended to the measurement of multiple residual-stress components by making multiple cuts with subsequent applications of superposition. The theory and limitations are described. The theory is experimentally tested on a 316L stainless steel disk with residual stresses induced by plastically indenting the central portion of the disk. The multiple-cut contour method results agree very well with independent measurements using neutron diffraction and with a computational, finite-element model of the indentation process.     

Comprehensive numerical analysis of a three-pass bead-in-slot weld and its critical validation using neutron and synchrotron diffraction residual stress measurements

The current paper presents a finite element simulation of the residual stress field associated with a three pass slot weld in an AISI 316LN austenitic stainless steel plate. The simulation is split into uncoupled thermal and mechanical analyses which enable a computationally less expensive solution. A dedicated welding heat source modelling tool is employed to calibrate the ellipsoidal Gaussian volumetric heat source by making use of extensive thermocouple measurements and metallographic analyses made during and after welding. The mechanical analysis employs the Lemaitre–Chaboche mixed hardening model. This captures the cyclic mechanical response which a material undergoes during the thermo-mechanical cycles imposed by the welding process. A close examination of the material behaviour at various locations in the sample during the welding process, clearly demonstrates the importance of defining the correct hardening and high temperature softening behaviour. The simulation is validated by two independent diffraction techniques. The well-established neutron diffraction technique and a very novel spiral slit X-ray synchrotron technique were used to measure the residual stress–strain field associated with the three-pass weld. The comparison between the model and the experiment reveals close agreement with no adjustable parameters and clearly validates the used modelling procedure.     

X-ray diffraction study of residual macrostresses in shot-peened and fatiqued 4130 steel

A study has been made of the effects of shot peening and fatigue cycling on the residual macrostresses determined by X-ray methods in an austenitized and tempered AISI 4130 steel (150–170 ksi). The results show that the effect of shot peening is to produce a residual compressive macrostress layer 0.014-in. deep. The residual-stress profile (stress vs. depth) exhibits a small negative stress gradient at and near the surface and a large positive stress gradient in the interior. Stress relaxation (due to fatique cycling) which occurred early in the fatigue history of the specimen was found greater at the surface than in the subsurface layers. Stress gradients of the stress profile increased with continued cycling and varied with depth. A correlation appears to exist between stress relaxation and stress gradients at the surface.     

Residual-stress distributions produced by strain-gage surface preparation

Abrasion of a metallic surface to improve bonding during strain-gage installation is generally thought to produce negligible effect on the measurement of residual stresses by blind hole drilling. However, residual stresses induced by surface abrasion may affect residual-stress measurements in shallow subsurface layers of residual-stress fields produced by processes such as grinding and shot peening.The residual-stress and cold-work distributions produced by four methods of abrasive surface preparation and etching were studied by X-ray diffraction in fully annealed AISI 1018 steel. The surface residual stresses produced by abrasion ranged from tension to compression with magnitudes as high as 80 percent of the yield strength. Cold work was induced to depths of 20 to 60 m. Etching produced low magnitude surface stresses and negligible cold work.Paper was presented at the 1986 SEM Spring Conference on Experimental Mechanics held in New Orleans, LA on June 8–13.     

Notch-root plastic response by temperature measurement

It is an experimental fact that the majority of the irreversible work of plastic deformation in metals is converted to heat. Under adiabatic conditions the spatial distribution of heating is indicative of the spatial distribution of plastic work. Tiny thermocouples welded directly to a metal surface were found to provide adequate measurement speed and sensitivity to detect the temperature change associated with plastic deformation. An array of thermocouples was used with some success in determining plastic-zone size. The heating response was used to study notch-root plastic deformation following overloads and following various post-overload heat treatments. The notch-root plastic response was correlated directly with the notch-root residual-stress level. The degree of stress relief as a function of time and temperature found in the notched members studied agrees well with predictions made using the Larson-Miller parameter and relaxation data on other steels. The deformation response in notched-member tests following stress relief is in qualitative agreement with that predicted by mechanics analysis of cracked bodies done by others.     

秦岭公路隧道2号竖井地应力与岩爆分析

利用水平圆柱形激波管对激波驱动的可压缩性气固两相流进行了试验研究. 利用压电式压力传感器、电荷放大器、示波器及计算机组成的压力信号测试系统, 对激波 与颗粒作用前后的气相参数进行测量及分析. 试验中测得了激波在管中的传播速 度, 波后气流的压力, 反射激波、透射激波的压力和速度等. 分别考察颗粒、装载 比、驱动气源以及入射激波马赫数等因素的差异对气相参数的影响. 试验结果表明: 激波与颗粒群相互作用时, 会产生反射激波和透射激波, 其强度与驱动气源、颗粒大小、颗粒装载比等参数有关; 激波衰减率随着装载比、马赫数的增大而减小. 研究指出, 在颗粒群被激波加速的初始阶段, 颗粒间的弹性碰撞起着重要的作用.