Residual Intensity as a Morphological Identifier of Twinning Fields in Microscopic Image Correlation

Experimental Mechanics - In the microscopic observation of deforming metals, it is well known that crystallite defects that accommodate strain can occasionally become visible, namely, they...     

Characterization and Control of Residual Stress and Curvature in Anodically Bonded Devices and Substrates with Etched Features

While anodic bonding is commonly used in a variety of microelectromechanical systems (MEMS) applications, devices and substrates that incorporate this processing technique are often subjected to significant residual stress and curvature that create post-processing and reliability issues. Here, using an anisothermal anodic bonding procedure, residual stresses and the resulting wafer curvature in these structures are controlled by varying the initial bond temperatures of the silicon and Pyrex wafers independently. Residual stresses are quantified by measuring bulk wafer curvature and, locally, stress concentrations are measured using infrared photoelasticity accompanied by 3-D thermomechanical finite element analysis. Based on the good agreement between numerical predictions and experimental results, this process can be used to determine the bulk post-bond wafer curvature and to reduce the likelihood of structural failure at these sites, by changing the residual stresses from tensile in nature, which may drive initiation and growth of cracks, to compressive, which can suppress such failures.     

The Equations of Motion of a Plate with Residual Stress

We consider a three-dimensional body which is at rest in a cylindrical configuration of height 2ε. We assume that the material is residually stressed and that it responds elastically to deformations from the reference configuration. Under appropriate assumptions on the data, and using weak-convergence methods, we determine the limit, as ε goes to zero, of the elasto-dynamic problem. The plate problem obtained, as in the case without residual stress, splits into two problems: one governing the in-plane displacement and the other determining the out-of-plane motion.     

Residual Stress State Characterization of Machined Components by X-ray Diffraction and Multiparameter Micromagnetic Methods

Machining induced residual stress states have been identified to affect the distortion of parts during following heat treatments. Thus, ideally a complete characterization of the components residual stress state is required. Magnetic and micromagnetic analysis of residual stresses can represent an important gain of time compared to X-ray diffraction. Investigations with these two methods were performed on different components with various and inhomogeneous residual stress states: cylindrical and tapered ball bearing rings made from AISI52100 steel and a disc made from AISI5210 steel. Reliable results and good agreement between X-ray diffraction data and residual stresses obtained from the magnetic and micromagnetic analysis can be obtained with the use of a calibration for each single component. An important gain of time can be achieved with the combined use of X-ray diffraction analysis for the calibration and the micromagnetic technique. However, local residual stress variations in zones smaller than the sensor size may not be detected. A global calibration of the micromagnetic equipment with one calibration file for several parts still needs optimization.     

Residual Stresses in a Shaft after Weld Repair and Subsequent Stress Relief

To evaluate the possibility of repairing and/or modifying shaft surfaces by welding, remachining, and low-temperature stress relieving without introducing high residual stresses, residual-stress measurements were made on an 8.0 in. diameter shaft of Type 347 stainless steel. The measurements were made on the shaft surface before welding, after welding and remachining, and after a 750°F stress relief. This report shows the residual-stress patterns in and near the weld area at the various stages of the investigation. Measurements were made using the hole-drilling method. The holes were 0.060 in. diameter and 0.06 in. deep. They were made using a unique, stress free abrasive jet machining technique.*     

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.     

Measurement of the Residual Stress Tensor in a Compact Tension Weld Specimen

Neutron diffraction measurements have been performed to determine the full residual stress tensor along the expected crack path in an austenitic stainless steel (Esshete 1250) compact tension weld specimen. A destructive slitting method was then implemented on the same specimen to measure the stress intensity factor profile associated with the residual stress field as a function of crack length. Finally deformations of the cut surfaces were measured to determine a contour map of the residual stresses in the specimen prior to the cut. The distributions of transverse residual stress measured by the three techniques are in close agreement. A peak tensile stress in excess of 600 MPa was found to be associated with an electron beam weld used to attach an extension piece to the test sample, which had been extracted from a pipe manual metal arc butt weld. The neutron diffraction measurements show that exceptionally high residual stress triaxiality is present at crack depths likely to be used for creep crack growth testing and where a peak stress intensity factor of 35 MPa√m was measured (crack depth of 21 mm). The neutron diffraction measurements identified maximum values of shear stress in the order of 50 MPa and showed that the principal stress directions were aligned to within ~20° of the specimen orthogonal axes. Furthermore it was confirmed that measurement of strains by neutron diffraction in just the three specimen orthogonal directions would have been sufficient to provide a reasonably accurate characterisation of the stress state in welded CT specimens.     

Assessment of Primary Slice Release Residual Stress Mapping in a Range of Specimen Types

This paper further explores the primary slice removal technique for planar mapping of multiple components of residual stress and describes application to specimens with a range of alloys, geometries, and stress distributions. Primary slice release (PSR) mapping is a combination of contour and slitting measurements that relies on decomposing the stress in a specimen into the stress remaining in a thin slice and the stress released when the slice is removed from a larger body. An initial contour method measurement determines a map of the out-of-plane stress on a plane of interest. Subsequently, removal of thin slices and a series of slitting measurements determines a map of one or both in-plane stress components. Four PSR biaxial mapping measurements were performed using an aluminum T-section, a stainless steel plate with a dissimilar metal slot-filled weld, a titanium plate with an electron beam slot-filled weld, and a nickel disk forging. Each PSR mapping measurement described herein has one (or more) complementary validation measurement to confirm the technique. Uncertainty estimates are included for both the PSR mapping measurements and the validation measurements. Agreement was found between the PSR mapping measurements and validation measurements showing that PSR mapping is a viable technique for measuring residual stress fields.     

Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

Cutting-induced plasticity can lead to elevated uncertainties in residual stress measurements made by the contour method. In this study plasticity-induced stress errors are numerically evaluated for a benchmark edge-welded beam to understand the underlying mechanism. Welding and cutting are sequentially simulated by finite element models which have been validated by previous experimental results. It is found that a cutting direction normal to the symmetry plane of the residual stress distribution can lead to a substantially asymmetrical back-calculated stress distribution, owing to cutting-induced plasticity. In general, the stresses at sample edges are most susceptible to error, particularly when the sample is restrained during cutting. Inadequate clamping (far from the plane of cut) can lead to highly concentrated plastic deformation in local regions, and consequently the back-calculated stresses have exceptionally high values and gradients at these locations. Furthermore, the overall stress distribution is skewed towards the end-of-cut side. Adequate clamping (close to the plane of cut) minimises errors in back-calculated stress which becomes insensitive to the cutting direction. For minimal constraint (i.e. solely preventing rigid body motion), the plastic deformation is relatively smoothly distributed, and an optimal cutting direction (i.e. cutting from the base material towards the weld region in a direction that falls within the residual stress symmetry plane) is identified by evaluating the magnitude of stress errors. These findings suggest that cutting process information is important for the evaluation of potential plasticity-induced errors in contour method results, and that the cutting direction and clamping strategy can be optimised with an understanding of their effects on plasticity and hence the back-calculated stresses.     

Intermethod Comparison and Evaluation of Measured Near Surface Residual Stress in Milled Aluminum

Background

While near surface residual stress (NSRS) from milling is a driver for distortion in aluminum parts there are few studies that directly compare available techniques for NSRS measurement.

Objective

We report application and assessment of four different techniques for evaluating residual stress versus depth in milled aluminum parts.

Methods

The four techniques are: hole-drilling, slotting, cos(α) x-ray diffraction (XRD), and sin²(ψ) XRD, all including incremental material removal to produce a stress versus depth profile. The milled aluminum parts are cut from stress-relieved plate, AA7050-T7451, with a range of table and tool speeds used to mill a large flat surface in several samples. NSRS measurements are made at specified locations on each sample.

Results

Resulting data show that NSRS from three techniques are in general agreement: hole-drilling, slotting, and sin²(ψ) XRD. At shallow depths (<?0.03 mm), sin²(ψ) XRD data have the best repeatability (<?15 MPa), but at larger depths (>?0.04 mm) hole-drilling and slotting have the best repeatability (<?10 MPa). NSRS data from cos(α) XRD differ from data provided by other techniques and the data are less repeatable. NSRS data for different milling parameters show that the depth of NSRS increases with feed per tooth and is unaffected by cutting speed.

Conclusion

Hole-drilling, slotting, and sin²(ψ) XRD provided comparable results when assessing milling-induced near surface residual stress in aluminum. Combining a simple distortion test, comprising removal of a 1 mm thick wafer at the milled surface, with a companion stress analysis showed that NSRS data from hole-drilling are most consistent with milling-induced distortion.

     

Supercritical Deformation and Fracture of Bodies with Concentrators under Plane Stress State Conditions

The paper deals with experimental studies of inhomogeneous strain fields with regions of supercritical behavior of the material in the case of extension of plane specimens of steel 20 with concentrators of different geometry by using the method of digital image correlation. The use of a video system permits obtaining experimental data about the distribution of the fields of longitudinal, transverse, and shear components and the strain intensity. The previously considered criteria for the deformation process transition to the supercritical stage for different types of the stress–strain state were used to distinguish the regions of supercritical behavior and to analyze the evolution of the strain and temperature fields in their stable development.     

Mapping Microscale Strain Fields Around a Crack Tip in Molybdenum Via Geometric Phase Analysis and Digital Image Correlation

Uniaxial tension tests were conducted on single-edge-notched tensile specimens of pure molybdenum with a mesh grid pattern in front of the notch. A series of images of crack initialization and propagation with a distorted mesh grid pattern were obtained by means of in situ scanning electron microscopy. Strain fields around the crack tip were mapped successively using geometric phase analysis and digital image correlation techniques, and then compared with the predictions obtained through linear elastic fracture mechanics(LEFM). The comparison shows that the measured strain distribution ahead of the crack tip is consistent with the LEFM predictions of up to 25 μm from the crack tip.     

埋入混凝土中压电陶瓷应力及温度特性研究

结构健康监测中对混凝土内应力的测量一直没有得到很好的解决。针对前期工作中提出的利用埋入式压电陶瓷进行混凝土内应力检测的方法,进一步研究了在埋入状态下,两种不同种类PZT压电陶瓷的应力及温度特性。分析了在温度实验中存在的应力-温度交叉传感现象的成因,并提出了温度补偿的方案,为今后完善应力测量方法奠定了基础。     

Measurement and Prediction of Machining Induced Redistribution of Residual Stress in the Aluminium Alloy 7449

The residual stress distributions in two 7449 aluminium alloy rectilinear blocks have been determined using neutron diffraction. Heat treatment included cold water immersion quenching and a period of precipitation hardening. Quenching induced very high magnitude residual stresses into the two blocks. One block was measured in this condition while the other was incrementally machined by milling to half thickness. Neutron diffraction measurements were made on the milled half thickness block at equivalent locations to the unmachined block. This permitted through thickness measurements from both blocks to be compared, revealing the redistribution of residual stresses induced by machining. A square cross section post in the centre of the machined face was left to act as a stress free reference sample. The distortions arising on the face opposite to that being milled were measured using a co-ordinate measuring machine. The residual stresses and distortion arising in the blocks have been compared to finite element analysis prediction and found to generally agree. Material removal only caused distortion and the residual stresses to redistribute; there was no stress relaxation evident.     

X-ray Diffraction Technique with Imaging Plate for Detecting Surface Distribution of Residual Stress in Diaphysis of Bovine Femurs

Stress measurements of bone are essential for evaluating the risk of bone fracture, the cure of bone diseases (e.g., osteoporosis), and the bone adaptation. Previously, a method using X-ray diffraction (XRD) was used to assess the presence of residual stress in the diaphysis of bovine and rabbit extremities. However, the previous method required a complicated experimental setup, long irradiation time, and limitations of the sample size. To profoundly enhance the understanding of distribution and biomechanical implications of bone residual stresses, it is necessary to develop an alternative method that features a simple setup without limitations on the sample size and shape. An imaging plate (IP) can obtain the two-dimensional distribution of hydroxyapatite crystal deformation and has the potential to resolve the previously mentioned issues. The aim of this study was to develop a measurement system using an XRD technique with an IP for obtaining the surface distribution of residual stress in the diaphysis of extremities. A mid-diaphysis specimen taken from an adult bovine femur was irradiated with characteristic Mo-Kα X-rays under no external forces and the diffracted X-rays were detected by an IP in the reflection side. The residual stress in the bone axis was calculated from the XRD pattern. As a result, tensile residual stresses were detected at the diaphyseal surface, corresponding to the results of the previous method. The developed system reduced the irradiation time by two thirds and the limitations of the sample size were removed.     

Identification of Heterogeneous Constitutive Parameters in a Welded Specimen: Uniform Stress and Virtual Fields Methods for Material Property Estimation

Local strain data obtained throughout the entire weld region encompassing both the weld nugget and heat affected zones (HAZs) are processed using two methodologies, uniform stress and virtual fields, to estimate specific heterogeneous material properties throughout the weld zone. Results indicate that (a) the heterogeneous stress–strain behavior obtained by using a relatively simple virtual fields model offers a theoretically sound approach for modeling stress–strain behavior in heterogeneous materials, (b) the local stress–strain results obtained using both a uniform stress assumption and a simplified uniaxial virtual fields model are in good agreement for strains ɛ _xx < 0.025, (c) the weld nugget region has a higher hardening coefficient, higher initial yield stress and a higher hardening exponent, consistent with the fact that the steel weld is overmatched and (d) for ɛ _xx > 0.025, strain localization occurs in the HAZ region of the specimen, resulting in necking and structural effects that complicate the extraction of local stress strain behavior using either of the relatively simple models.

Hydrodynamic and Thermal Fields in a Porous Medium with Injection of Superheated Steam

The plane one-dimensional and radially symmetric problems of injection of superheated steam into a porous medium saturated with gas are considered. Self-similar solutions are constructed on the assumption that in this case four zones are formed in the porous medium, namely, a gas flow zone, superheated and wet steam zones, and a water slug zone formed due to steam condensation. On the basis of the solution obtained, both the effects of the boundary pressure, mass flow rate, and temperature of the injected superheated steam and the effect of the initial state of the porous medium on the propagation of the hydrodynamic and thermal fields in the porous medium are studied.     

Stress Reconstruction and Constitutive Parameter Identification in Plane-Stress Elasto-plastic Problems Using Surface Measurements of Deformation Fields

This paper deals with the identification of elasto-plastic constitutive parameters from deformation fields measured over the surface of thin flat specimens with the grid method. The approach for recovering the constitutive parameters is the virtual fields method. A dedicated algorithm is used for deriving the distribution of the 2D stress components from the measured deformation fields. A state of plane stress is assumed. Guesses of the constitutive parameters are input in the algorithm and updated until the stresses satisfy the principle of virtual work in the least squares sense. The advantage of this approach is that it can handle very heterogeneous plastic flows and it is much faster than classical finite element model updating approaches. An experimental application is provided to demonstrate it. Six mild steel double-notched specimens have been tested in a configuration combining tension and in-plane bending. The identified parameters are in good agreement with their reference counterparts. Stress fields are eventually reconstructed across the specimen all along the test for analyzing the evolution of the plastic flow.     

Neutron Diffraction Analysis of Complete Residual Stress Tensors in Conventional and Rolled Gas Metal Arc Welds

Mitigation of residual stress in an arc weld by high-pressure rolling of the weld seam has been investigated using neutron diffraction. Rolling was found to greatly improve the residual stress distribution, causing significant compressive stresses at the weld line. A novel aspect of the data presented is that at each measurement location, normal strains in nine separate directions were evaluated, enabling calculation of the complete strain and stress tensors. It is thus confirmed that the principal stress directions generally lay close to the specimen coordinate axes (i.e. that they are well-aligned with the direction of welding and rolling), and that rolling does not cause any significant additional residual stresses which could have detrimental effects. Methods of uncertainty estimation and the applications of full-tensor residual stress measurements are also discussed.