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.     

Comparison of residual-stress variation with depth-analysis techniques for the hole-drilling method

Numerous data-analysis techniques have been developed to determine residual-stress information from strain data obtained from the hole-drilling method. The most commonly used technique for data analysis was developed by Rendler and Vigness (which forms the basis of the standard described in ASTM E837-85). A numerical development which was a model of the hole-drilling procedure has been used to determine stress variation with depth. A rigorous finite-element method to specifically analyze stresses in discrete hole increments has been developed. To evaluate these data-analysis techniques, three different computer-simulated stress fields are compared. The stress fields include a uniaxial stress that is constant with depth, a bending stress that varies linearly with depth, and a subsurface stress reversal. (The basis for this comparison is a finite-element developed technique. Its accuracy will be discussed later.) All data-analysis techniques showed excellent agreement for the uniaxial stress constant with depth test case. However, for the other two stress fields, significant discrepancies were apparent. Results are compared and discussed.     

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.     

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.     

Comparison of three residual-stress measurement methods on a mild steel bar

The objective of this investigation was to ascertain the surface residual-stress condition of a specially thermal-mechanically treated mild steel bar. Three methods of residual-stress measurement were used—two of them accurate, well-verified approaches and the third an experimental one. The first two were stress-relief blind-hole drilling (SRT) and X-ray diffraction (XRD), and the third was Barkhausen noise analysis (BNA). It is difficult to make direct comparisons between these methods since they each sample a different volume of material at different depths into the surface. However, the SRT data, when extrapolated to shallow depths sampled by the XRD, show excellent agreement with that nondestructive method. The BNA results show poor correlation with the XRD and SRT even with extrapolation to similar depths. The major reason for the poor BNA results seems to be its sensitivity to the microstructural conditions of the sample. All of the measurements, with the exception of one set of BNA measurements, indicate that tensile stresses existed in the surface of the specimen.     

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.     

General stress-velocity expressions in acoustoelasticity

The velocity of a transverse wave propagating in an elastic body depends on the stress field of the body. If transverse waves are sent through a body with a uniaxial stress field, there will be proportionality between the principal-stress difference and the relative velocity difference between the waves polarized in accordance with the two main directions. This technique is used for determining uniaxial residual-stress fields. The main object of the investigation described in this paper has been to investigate the usefulness of the method in the case of biaxial residual-stress fields. Both theoretically and experimentally, the investigation has shown that there is also proportionality between principal-stress difference and relative-velocity difference for a biaxial field. However, the tests have also shown that inaccuracies with this method, on account for example of preferred orientation in steel materials, are of such an order of magnitude that the method cannot, at the present stage of development, compete with the more traditional methods, such as the drilling method and the X-ray diffraction method.     

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.*     

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.     

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.     

Stress Monitoring of Post-processed MEMS Silicon Microbridge Structures Using Raman Spectroscopy

Inherent residual stresses during material deposition can have profound effects on the functionality and reliability of fabricated Micro-Electro-Mechanical Systems (MEMS) devices. Residual stress often causes device failure due to curling, buckling, or fracture. Typically, the material properties of thin films used in surface micromachining are not well controlled during deposition. The residual stress; for example, tends to vary significantly for different deposition methods. Currently, few nondestructive techniques are available to measure residual stress in MEMS devices prior to the final release etch. In this research, micro-Raman spectroscopy is used to measure the residual stresses in polysilicon MEMS microbridge devices. This measurement technique was selected since it is nondestructive, fast, and provides the potential for in-situ stress monitoring. Raman spectroscopy residual stress profiles on unreleased and released MEMS microbridge beams are compared to analytical and FEM models to assess the viability of micro-Raman spectroscopy as an in-situ stress measurement technique. Raman spectroscopy was used during post-processing phosphorus ion implants on unreleased MEMS devices to investigate and monitor residual stress levels at key points during the post-processing sequences. As observed through Raman stress profiles and verified using on-chip test structures, the post-processing implants and accompanying anneals resulted in residual stress relaxation of over 90%.     

A multilayer-reflection technique for three-dimensional photoelastic studies of perforated plates in bending

A photoelastic investigation was conducted to determine the stress-concentration factors around a large, symmetrically reinforced central hole in a square plate under 1∶1 and 2∶1 biaxial bending. Tapered-edge rings served as the reinforcement, and a major objective was to determine the ring proportions such that the maximum stress at the hole would be equal to the value which would be present in an unperforated plate under the same nominal stress. Because the stress distribution at the periphery of a hole in such a plate structure varies in the radial, tangential and thickness direction, it was necessary to employ a three-dimensional photoelastic technique. There were a number of serious disadvantages in the use of any of the standard procedures and a new three-dimensional technique for room-temperature use was developed which is particularly suitable for the determination of boundary stresses around holes in bending experiments. With the technique in its present state of development, the three-dimensional isochromatic distribution in the plate can be determined from a single model and, from this, the boundary value of stress. The new technique utilized a laminated-plate model. Selective aluminizing of the laminations allowed for the determination of fringe-order distributions in the thickness direction as well as in the radial and circumferential directions at the boundary of the hole in flat models. Uniaxial maximum fringe orders were determined and, from these, the biaxial values were obtained by superposition.     

Examination of the computational model for the layer-removal method for residual-stress measurement

An analytical solution is presented to examine the accuracy of the ‘layer-removal’ method for measuring localized residual stresses. In this approach, strips, which may have been cut from a pipe or a plate, have strain-gage rosettes placed on one face and layers removed from the other face. The strain measurements are used to deduce the residual stress in the layers removed. The stress measured is that along the axis of the strip. It may vary rapidly with axial distance, as for example when the strip is taken from a welded part. The present analysis shows that the actual stress distribution may be quite different from that predicted by the computational model normally used in the layer-removal method. It shows that the difference increases as the ratio of the heighth of the strip from which a layer is removed to the half dimensiona of the localized residual-stress zone increases. It is recommended that the layer-removal method can be used for measuring residual stresses for cases in which the ratio ofh/a is less than or equal to unity.     

剪切散斑:一种光学测量技术及其应用

本文综述了剪切散斑测量技术及其成功的应用领域。剪切散斑技术是一种基于激光的全场、非接触表面变形(位移或应变)测量技术,它无需特殊的隔震装置,克服了因参考光束给全息干涉技术所带来的诸多限制。因此,它是用于现场测量的一个有效工具。剪切散斑测量技术已经得到了工业界的普遍认同,尤其是在工业无损检测方面更显示出了它的极大优势,它可以通过识别被诱发的异常变形来显示物体的内部缺陷。剪切散斑的应用还包括应变测量、材料特性表征、残余应力评估、泄漏探测、振动分析和三维形貌测量等。     

Effect of constraint induced by crack depth on creep crack-tip stress field in CT specimens

In this paper, the effect of constraint induced by the crack depth on creep crack-tip stress field in compact tension (CT) specimens is examined by finite element analysis, and the effect of creep deformation and damage on the Hutchinson–Rice–Rosengren (HRR) singularity stress field are discussed. The results show the constraint induced by crack depth causes the difference in crack-tip opening stress distributions between the specimens with different crack depth at the same C*. The maximum opening stress appears at a distance from crack tips, and the stress singularity near the crack tips does not exist due to the crack-tip blunting caused by the large creep deformation in the vicinity of the crack tips. The actual stress calculated by the finite element method (FEM) in front of crack tip is significantly lower than that predicted by the HRR field. Based on the reference stress field in the deep crack CT specimen with high constraint, a new constraint parameter R is defined and the constraint effect in the shallow crack specimen is examined at different distances ahead of the crack tip from transient to steady-state creep conditions. During the early stages of creep constraint increases with time, and then approaches a steady state value as time increases. With increasing the distance from crack tips and applied load, the negative R increases and the constraint decreases.     

Residual-stress analysis of an epoxy plate subjected to rapid cooling on both surfaces

This paper presents theoretical and experimental methods of finding the residual stress in an epoxy plate subjected to rapid cooling on both surfaces. The theoretical residual-stress distributions in a plate are calculated by using the fundamental equations based on the linear viscoelastic theory. The specimens in the experiment are subjected to rapid cooling. The residual stresses are measured by the layer-removal method. The theoretical and experimental results are compared and discussed.     

Analysis of residual stresses in cylindrically anisotropic materials

Metal-forming operations leave residual stresses in formed parts due to nonuniform deformation occurring during the process. An exact method of determining the longitudinal, radial and circumferential (tangential) residual stresses in axisymmetric specimens was proposed by Mesnager¹ and further developed by Sachs². The boring-out technique can be complemented by a similar procedure in which strains are measured on the inner surface of the tube when material is removed from the outer surface.The work proposed in this paper extends previous analyses of residual stresses to the case where the material exhibits cylindrical elastic anisotropy, i.e., the principal axes of anisotropy correspond to the longitudinal, radial and circum-ferential directions of the tube. In addition, the present analysis considers the case in which a residual-shear stress, developed by twisting the tube about its axis, exists in the tube. When such shearing stresses are present, the principal axes of the residual-stress distribution are not parallel to the principal axes of the tube.     

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