An investigation of the use of strain gages to measure welding-induced residual stresses

The measurement of weld-induced residual stress is important in structures that are subjected to cyclic loading during their service life. Depending on their magnitude, stresses can influence the rate of crack growth under cyclic loading and hence affect the life of the structure. Because the level of residual stress may change during service, measurement of these changes is necessary for accurate life prediction of the structures. The measurement of welding-induced residual stress using strain gages poses significant problems, the most important being the potential damage to the gages by high temperatures generated in the welding process. This laboratory study was undertaken to assess the suitability and signal stability of commercially available resistive strain gages for the measurement of postweld residual stresses in a submarine hull structure. Adhesively bonded and weldable-type strain gages were attached to the surface of a 35 mm thick steel plate, which was then subjected to thermal cycles similar to those encountered during welding construction of a submarine pressure hull. This paper describes the strain gage application procedure, changes in the strain gage output at end of each experimental stage and the history of changes in the residual stress.     

Embedded optical fiber Bragg grating sensor in a nonuniform strain field: Measurements and simulations

This paper investigates the use of embedded optical fiber Bragg gratings to measure strain near a stress concentration within a solid structure. Due to the nature of a stress concentration (i.e., the strong nonuniformity of the strain field), the assumption that the grating spectrum in reflection remains a single peak with a constant bandwidth is not valid. Compact tension specimens including a controlled notch shape are fabricated, and optical fiber Bragg gratings with different gage lengths are embedded near the notch tip. The form of the spectra in transmission varies between gages that are at different distances from the notch tip under given loading conditions. This variation is shown to be due to the difference in the distribution of strain along the gage length. By using the strain field measured using electronic speckle pattern interferometry on the specimen surface and a discretized model of the grating, the spectra in transmission are then calculated analytically. For a known strain distribution, it is then shown that one can determine the magnitude of the applied force on the specimen. Thus, by considering the nonuniformity of the strain field, the optical fiber Bragg gage functions well as an embedded strain gage near the stress concentration.     

In situ determination of adhesive shear moduli using strain gages

A new, convenient and cost-effective method of determining in situ adhesive shear moduli using strain gages is proposed and evaluated. Thick-adherend lap shear specimens with stacked gage rosettes at the center of the bond line are loaded in tension for adhesive shear strain measurement. Experimental and numerical results indicate that the test specimen has a nonuniform adhesive shear stress (or strain) distribution in the test section and that this distribution (except at the center point of the bond line) is greatly affected by load eccentricity. In addition to the nonuniformity in the shear stress distribution, the issue of material nonhomogeneity in the gage-covered region affects the strain gage measurement. By taking into account these two issues and assuming linear-elastic behavior, two approaches for converting the gage-measured shear strain into the adhesive shear strain are developed and verified by experiment. It is shown that the strain gage measurement associated with either of two conversion techniques can determine the in situ adhesive shear moduli, which are comparable with moiré experiment and KRG-1 extensometer measurements.     

Use of electrical-resistance strain elements in three-dimensional stress analysis

A method for constructing resistance-wire strain gages which may be imbedded in a plastic model without materially altering the stress pattern in the model is presented. The methods used to calibrate the gages and the photoelastic tests made to investigate the effect of the gages on the stress pattern are described. The application of this new three-dimensional technique to evaluate the stress distribution in a thick-walled cylindrical pressure vessel is discussed. Correlation between experimental data and calculated values is given.     

Development of a machine integrated strain-based contact force sensor for pad foot soil compactors

An investigation was undertaken to explore the use of measurable pad strains on a non-vibratory pad foot roller to provide real time continuous evidence of compaction and contact force. Individual pads were instrumented with strain gages in a pattern chosen based on pad finite element analysis (FEA). Different pad–soil contact stress distributions were modeled to simulate a range of soil conditions. The FEA revealed that the contact stress distribution has a significant influence on the observed pad strain field, suggesting soil specific interpretation of pad strains in order to determine contact force. Results from uniaxial laboratory testing of pad loading on dry sand verified the FEA, i.e., experimental strains generally matched within 15% of FEA strains. The contact stress distribution was measured using tactile pressure sensors and found to be moderately parabolic. A soil specific empirical calibration factor relating vertical sidewall strains to contact force was determined. Field testing was performed on the dry sand with multiple instrumented pads installed on a Caterpillar CP56 roller. Pad strain magnitudes increased up to 250% during compaction from repeated passes of the roller. Using the empirical calibration factor, the estimated contact force was shown to increase with compaction, represented by the independently-measured soil unit weight.     

Experimental study of large-diameter thin-wall pressure vessels

An experimental stress analysis of three cylindrical pressure vessels with radius/thickness ratios ranging from 100 to 238 and different head closures is described. Brittle coatings and electrical strain gages were employed to determine stress distributions over the entire outer surface of the vessels. Electrical strain gages alone were used to determine stresses on the inside surface of the vessels. Particular emphasis was placed on determining stress concentrations and on nonlinear effects produced by geometric imperfections. An attempt was also made to correlate the failure, which started in the cylindrical portion of the three vessels, with the elastic-stress distribution. It was found that the imperfections in the cylinder were not significant if the vessel was fabricated from a ductile steel. However, if the vessel was constructed from a high-strength but brittle steel, the imperfections significantly lower the bursting strength of the vessel.     

Strain gages for long-term high-temperature strain measurement

The capabilities of resistance and capacitance strain gages for use in the temperature range of 1100–1400°F for durations up to 10,000 h are reviewed. Characteristics are given in summary and tabular form along with a list of references. Resistance strain gages offer some capability under these conditions, but the newer capacitance gages show promise for both laboratory and field use at high temperatures.     

A highly sensitive noncontacting electromagnetic device for detecting dynamic stress in structures

A highly sensitive, noncontacting electromagnetic device has been developed to detect stress waves in structures. It is shown that for detecting an induced strain this device is over 500 times more sensitive than conventional bonded strain gages. The principle of detecting the strain by this device is based on the fact that dynamic stresses in a structure induce similar stresses in a bonded piezoelectric material. This, in turn, creates a magnetic field which extends beyond the material itself. An electromagnetic device has been built to detect this magnetic field and thus monitor the dynamic stresses. This method provides a noncontacting means of measuring strain in structures with improved sensitivity.     

Strain-gage instrumentation for ammunition testing

This paper deals with a feasibility study on the use of electrical-resistance strain gages for quality-assurance testing of ammunition. A special combination of strain gages was selected to measure the quantity ( \( \in _\theta + v \in _z \) ) on the outer surface of a test barrel. This combination of strain gages was essentially a stress gage which has several advantages over commercially available types. The combined strain signal was proportional to \(\sigma _\theta \) which was related to the internal ballistic pressure. The results of ballistic firings and hydraulic tests are reported which demonstrate the feasibility of this method for acceptance testing of ammunition.     

Enhanced measurement of strain distributions

A theoretical approach is presented that uses multiple strain gages to accurately measure complicated strain distributions. The technique is based on the method of weighted residuals in conjunction with measured strain data and is applicable for arbitrary in-plane strain distributions. Conventional measurements using strain gages are shown to represent a particular case of the approach presented. The experimental characterization of unidimensional strain fields is discussed in detail. Two approaches are presented; these are based on linear and quadratic approximations of the strain field. The strain distribution for two important practical problems is evaluated assuming ideal conditions to assess the performance of the proposed approach. In both cases, the simulated results demonstrate that measurement error resulting from the finite size of a strain gage may be reduced. That is, a larger strain gage may be used for a given maximum admissible error. The method also allows a minimal error of measured nonlinear strains.     

Stress concentrations around multiple windows in a high-pressure vessel

A pressure vessel with four radial windows was designed in which to conduct equation-of-state experiments at pressures up to 1 GPa (145,000 psi). To determine the relative safety of the vessel, the stress distribution in the cylindrical sidewalls, particularly the stress concentration near the window openings, was studied. Conventional analysis was used for the initial evaluation but was found to give somewhat higher stress values than were actually present. Better determinations of the stress distribution were obtained by photoelastic analysis of a model of the pressurevessel linear and by proof tests with strain gages of the actual liner and the assembled pressure vessel. Apparently, the tapered sapphire windows, loaded in compression by the internal pressure in the vessel, modify the stress distribution sufficiently to allow operation at higher pressures than otherwise would be attainable. Design features of the pressure vessel are presented, together with a synoptic stress analysis, a photoelastic analysis, and results of the strain-gage studies.     

由应力集中处附近的应变值推求最大应力的一种方法

本文提出了一种用电阻片测定构件应力集中处最大应力的方案,以及相应的数据处理公式。典型实测与算例表明,本方法具有精度高的特点。并可以用于有限元、光弹性、云纹等方法。     

Errors in high-temperature strain measurements

The results of a technical evaluation of the accuracy of two types of commercially available high-temperature electric-resistance strain gages, and a special high-temperature gage under development at the Liquid Metal Engineering Center (LMEC) are presented. These gages, the BLH type HT 1212-5A, Microdot type SG420, and the LMEC gage, were selected for evaluation because of the need for reliable electric-resistance strain gages for high-temperature stress or strain measurements and process instrumentation in the temperature range of 900 to 1200° F. The BLH gage is rated by the manufacturer as a 1000 to 1200° F gage; the Microdot gage is rated as a 900° F gage. The special LMEC gage was made for use up to 1200° F. Instrumentation of this type is needed to determine or ensure component structural integrity and over-all system reliability of fast breeder reactors.     

Reversible strain gage

A reversible strain gage was developed for accurately measuring thermal strains, especially for use on large structures where strain gages cannot be welded. These strain gages can be peeled after taking required apparentstrain measurements in a furnace and can be attached reverse-side-up at the points of interest on a test structure. After many trials, a polyimide strain gage was developed that is the same on both the base side and the cover side. The thermal characteristics of the reversible strain gage—repeatability of apparent strain, gage-factor change, creep, drift and the output for a given mechanical strain—were investigated. The repeatability of apparent strains for 100 reversible gages was within 60 microstrain of difference at 250°C. The output of reversible gages for mechanical strain, after 2 to 3 heat cycles which were peeled and cemented in the reverse-side-up position, almost coincided with those of virgin reversible gages.Paper was presented at Fourth SESA International Congress on Experimental Mechanics held in Boston, MA on May 25–30, 1980     

Development and design of new methods of measurement of state of strain of structures

The present paper deals with development and design of new methods utilizing Wiedemann's effect for determination of state of strain in building structures. Wiedemann's effect and some features of torsional strain of magnetic field are the basis of new experimental method. Especially the point electromagnetic strain gages using the effect of pure torsion of electromagnetic field to enable universal examination. For strain-gage measurements, almost all physical quantities are used which can be related to the variation in length of the structures. From the electric strain measurements, the most commonly used methods are the measurements by resonance-wire strain gages or by electric-resistance strain gages. In this paper, electromagnetic strain gages are discussed using the Wiedemann effect, and the author describes some new measuring equipment and his own suggestions and methods based on an application of this effect.     

Determining all Displacements,Strains and Stresses Full-Field from Measured Values of a Single Displacement Component

The ability to determine the individual components of displacement, strain and stress from measured values of a single component of displacement is demonstrated. Advantages of the method include its ability to significantly simplify the experimental technique by measuring only a single displacement component, to provide reliable results both full-field and at the edge of geometric discontinuities, and the lack of need to differentiate the recorded data physically. Results agree with those from thermoelastic stress analysis, strain gages and finite element analysis.     

The accuracy of residual stress measurement by the hole-drilling method

This paper describes the verification of the accuracy of residual stress measurement by the hole-drilling method. The strain measurement is simulated by the use of the indirect fictitious-boundary integral method. As an example, a finite rectangular plate subjected to initial stress is treated, and a simulated measurement of the residual stress is made using the strain relieved during hole drilling. The accuracy of residual stress measurement is estimated by comparing the simulated measured residual stress with the actual residual stress, i.e., the given initial stress. The results are shown for various distances and angles of strain gages. Also, the influences of the eccentricity of the hole from the center of the strain gages and the effect of a boundary near the hole are examined.     

Temperature and rise-time effects on dynamic strain measurement

Strain pulses in a test specimen were measured over a temperature range of ?73 to +149°C with foil and semiconductor strain gages. These tests were performed to determine if the rise time and amplitude of the gage output change as a function of temperature. The existence of a constant that should be added to the theoretical rise times of resistance strain gages, as suggested by Koshiro Oi, was reexamined. ‘Long’ rise-time strain pulses were produced in the test specimen by an impacting steel ball. The rise times of these pulses were on the order of 7 μs and the amplitudes were approximately 65 μm/m. The results of these tests show that the rise time and amplitude of the gage do not change as a function of temperature. ‘Short’ rise-time strain pulses of approximately 500 μm/m with a rise time of 2 μs were produced in a test specimen by a short pendulum-type hammer apparatus. The results of these tests showed that the amplitude of the gage output was relatively independent of test temperatures but exhibited a slight hysteresis effect. The rise times for these tests remained constant up to a temperature of 93°C, then started to increase. The rise times at 149°C were approximately 100 percent longer than at room temperature. Under optimum conditions, a pulse with a measured rise time of 0.18 μs could be generated. The results of these tests indicated that the theoretical rise-time additive constant of resistance strain gages is 0.05 μs or less. This is one-half the value that Bickle arrived at by reevaluating Oi's data. However, since the real rise time of the pulse was unknown, this additive constant is not necessarily a property of the gage.     

Doubly Reinforcing Cementitious Beams with Instrumented Hollow Carbon Fiber Tendons

Surface mounted strain gages are used to characterize the behavior of polymer-enhanced cementitious beams designed to withstand reverse loadings. These unique composite structures are doubly reinforced with hollow carbon fiber (graphite) tendons equipped with strain gages and the study includes section design, materials considerations, structural testing, and finite element analysis. The primary purpose of strain gage integration is to insure that the stress in the materials remains within the elastic range so that damage does not occur. A finite element model is developed to characterize the structural response in the elastic range and a hybrid approach is suggested in which displacement, strain, and stress can be obtained with a single strain gage. The ability to characterize structural performance beyond the elastic range is also demonstrated by analyzing data obtained from displacement-controlled tests.