Surface Residual Stress Measurement Using Curvature Interferometry

Surface roughness plays an important role in the delamination wear caused by rough surface contact. A recent dislocation model analysis predicts that nano-scale contacts of surface steps induce nucleation of dislocations leading to pro-load and anti-load dislocation segregation near the contact surface. Such dislocation segregation generates a sub-layer of tensile residual stress in a much thicker layer of compressive residual stress near the surface. The tensile sub-layer thickness is expected to be about 50 to 100 times the step height. In order to verify the predictions of the model analysis, contact experiments are carried out on polycrystalline aluminum surface to determine the existence of the tensile sub-layer. The variation of the residual stress along the thickness direction is measured using a newly developed high sensitivity curvature-measurement interferometer. The residual stress distribution measured with sub-nanometer spatial resolution indicates that contact loading leads to formation of a highly stressed sub-layer of tensile residual stress within a much thicker layer of compressive residual stress. Implications of tensile residual stress for delamination wear are discussed.     

Stress Level Measurement in Prestressed Steel Strands Using Acoustoelastic Effect

In-situ health monitoring of the tensioning components such as strands, tendons, bars, anchorage bolts, etc. used in civil engineering structures, namely bridges, dams, nuclear power plants, etc. is extremely important to ensure security of users and environment. This paper deals with a guided ultrasonic wave procedure for monitoring the stress levels in seven-wire steel strands (15.7 mm in diameter). For this purpose, simplified acoustoelastic formulations were derived from the acoustoelasticity theory and acoustoelastic measurements were performed. The results from acoustoelastic calibration tests and an anchorage block of seven-wire steel strands are presented and discussed. They show the potential and the suitability of the proposed guided wave method for evaluating the service stress levels in the prestressed seven-wire steel strands.     

Thermal Stress Measurement in Continuous Welded Rails Using the Hole-Drilling Method

The absence of expansion joints in Continuous Welded Rail has created the need for the railroad industry to determine the in-situ thermal stress levels for rail buckling and breakage prevention. This paper explores the hole-drilling method as a possible solution to this problem. A new set of calibration coefficients to compute the stress field relieved by fine hole depth increments required by the high strength steel was determined. The new calibration coefficients were experimentally validated on an aluminum plate subjected to a known uniaxial load. The thermal stress levels of constrained rails were estimated after compensation for the residual stress components, based on statistical relationships developed experimentally between the longitudinal and the vertical residual stresses. The results showed that the hole-drilling procedure, with appropriate calibration coefficients and residual stress compensation, can estimate the in-situ rail thermal stresses with an expected accuracy that is within the industry acceptable levels.     

Hole-Drilling Residual Stress Measurement with Artifact Correction Using Full-Field DIC

A full-field, multi-axial computation technique is described for determining residual stresses using the hole-drilling method with DIC. The computational method takes advantage of the large quantity of data available from full-field images to ameliorate the effect of modest deformation sensitivity of DIC measurements. It also provides uniform residual stress sensitivity in all in-plane directions and accounts for artifacts that commonly occur within experimental measurements. These artifacts include image shift, stretch and shear. The calculation method uses a large fraction of the pixels available within the measured images and requires minimal human guidance in its operation. The method is demonstrated using measurements where residual stresses are made on a microscopic scale with hole drilling done using a Focused Ion Beam – Scanning Electron Microscope (FIB-SEM). This is a very challenging application because SEM images are subject to fluctuations that can introduce large artifacts when using DIC. Several series of measurements are described to illustrate the operation and effectiveness of the proposed residual stress computation technique.     

Residual Stress Measurement in Composite Laminates Using Incremental Hole-Drilling with Power Series

Current methods for incremental hole-drilling in composite laminates have not been successfully applied in laminates of arbitrary construction or where significant variation of residual stress exists within a single ply. This work presents a method to overcome these limitations. Series expansion is applied to each ply orientation separately so that the discontinuities in the residual stresses at ply interfaces can be correctly captured. Temperature variations described by power series are used to set up eigenstrains and consequent stresses which vary in the through-thickness direction. The calibration coefficients at each incremental hole depth are calculated through the use of finite element modelling. The inverse solution employs a least-squares approach which makes the resulting solution insensitive to measurement uncertainty. Robust uncertainties in the residual stress distributions are determined using Monte Carlo simulation. The residual stress distribution is found from that combination of series orders in the different ply orientations that has the lowest RMS uncertainty, selected only from those combinations that have converged. The method is demonstrated on a GFRP laminate of [0₂/+45/?45]_s construction where it is found that transverse cracking of the plies at the inner surface of the hole may have impacted on the accuracy of the results.     

Residual Stress Measurement Using Hole Drilling and Integrated Digital Image Correlation Techniques

The effectiveness of optical (mostly interferometric) methods for the measurement of residual stresses is largely demonstrated in literature. Nevertheless, these techniques are still confined to optical laboratories due to their high sensitivity to vibrations which makes it very difficult to perform the measurement in an industrial environment. Digital Image Correlation (DIC) has recently been proposed as a possible solution to this problem: this non-interferometric technique is much less affected by vibrations, but its sensitivity is relatively low, thus negatively affecting the accuracy of results. This work proposes to use a variant of Digital Image Correlation, known as Integrated DIC (iDIC), in combination with the hole drilling technique. Since iDIC directly incorporates in its formulation the displacement field related to hole drilling, it overcomes most of the problems of standard DIC; in this way it is possible to obtain accurate results without using interferometric techniques.     

用应力波方法,测定粘弹性材料的动态力学性能

本文用粘弹性材料中应力波的弥散及衰减特性的实验数据来计算材料的动态力学性能参数。用塑料杆的纵波实验,测定了材料的拉压复柔量,并探讨了用横波实验测定材料剪切复模量的方法及有关问题。由测定结果在理论分析中应用,讨论了结果的可靠性。     

耐磨胶粘涂层固化残余应力的测试分析

将多根电阻丝平行于界面预埋在耐磨涂层中不同深度处，通过半桥电路测定了相应深度处涂层的固化残余应力。结果表明，紧接界面处耐磨胶粘涂层的残余应力最高，自界面开始处外约０．５ｍｍ层厚范围内的残余应力逐渐减小，可见涂层的固化残余应力主要来自底材表面对其固化收缩的阻碍效应。用适量的橡胶增韧是减小耐磨胶粘涂层固化残余应力的可行途径。     

Methodology for the Stress Measurement of Ferromagnetic Materials by Using Magneto Acoustic Emission

Magneto acoustic emission (MAE) is a magnetic nondestructive testing (NDT) method that has been used in different fields for 30 years. MAE is a promising method for the early characterization of damage and the evaluation of the residual stress of ferromagnetic materials. However, this technique is still in its early stage and requires further development. The mechanism and influence factors of MAE are still under investigation. Quantitative NDT is difficult because of the lack of robust theoretical bases and models. In this study, we investigated the influence factors of MAE signals systematically and established a mathematical model to describe these influences. The special design of the specimen and the precise control of experimental conditions are the key points for obtaining reasonable experimental results and for developing the model. A methodology for stress assessment was developed on the basis of the proposed model and was verified by using the pure bending test. Results show that stresses within a measureable depth of 4 mm can be evaluated and that the maximum testing error is 30 %.     

声弹性应力测量

本文简要评述了声弹性应力测量方法的理论、实验技术和应用等方面的发展概况。平面声弹性技术已取得进展。声弹性用于三维应力和残余应力测量仍有不少困难。     

Thermoelastic Stress and Damage Analysis Using Transient Loading

Thermoelastic stress analysis (TSA) is often regarded as a laboratory based technique due to its requirement for a cyclic load. A modified methodology is proposed in which only a single transient load is used for the TSA measurement. Two methods of imparting the transient load are validated against calculations and the conventional TSA approach. Specimens with different damage severities are tested and it is shown that the modified TSA method has the potential to be applied in the field as a non-destructive evaluation tool.     

超声表面波检测金属材料表面应力的实验研究

本文应用声弹性理论研究了表面波在金属材料表面的传播速度和表面应力之间的关系,优化了表面波声弹性公式,建立了应力和表面波相对传播时间差的关系。通过构造实用的微型表面波探头,采用数字相关法计算了不同应力下的表面被传播时间差,确定了A3钢的表面波传播时间差与应力的关系式。同时分析了试件表面粗糙度和平整度对表面波速度变化的影响,最后给出了金属材料在不同表面条件下的实验分析结果。     

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.

     

珠形爆炸容器水压试验应力测试及分析

设计压力12MPa的球形爆炸容器内径1m,壁厚2.5×10-2m,在3,6,9,12,15和0MPa的水压试验条件下,对其外表面具有代表性的20个测点进行了应力测试.并用三维ANSYS有限元编码对12和15MPa两种工况进行了应力分析,分析结果与测试结果基本吻合,这表明爆炸容器在整个试验压力范围是处于线弹性状态,容器的强度设计是合理的.     

Residual Stress Analysis of Orthotropic Materials Using Integrated Digital Image Correlation

Measuring residual stress in an orthotropic material is a difficult task due to the complex behavior of the material. Recently, two different approaches based on Smith’s simplified real value formulation and the general solution developed by Lekhnitskii have been proposed. Both solutions assume the measurement of the displacement field via interferometric optical methods and estimate stress values through solving an inverse problem. However, the high sensitivity to vibrations of interferometric techniques makes their use difficult outside optical laboratories; standard Digital Image Correlation could be used, but its low sensitivity and relatively high standard deviation of displacements severely affect the reliability of estimates. In this work we propose to integrate the residual stress displacement functions related to orthotropic materials into the shape functions of Digital Image Correlation. This makes it possible overcome most of the problems related to low sensitivity and large standard deviation because a single large patch can be used for the measurement, thus providing an accurate and reliable algoritm for the measurement of residual stress.     

叠片式气体箔片推力轴承热特性分析

叠片式气体箔片推力轴承具有制造工艺简单、散热能力强等优点,针对该新型轴承提出了相应的热特性分析模型,通过数值仿真分析得到轴承气膜及各元件的温度,并对关键影响参数进行了重点分析. 研究结果表明:由于气膜在半径较大位置处的线速度大,其剪切产热效果明显,温度越高,气膜的高温区分布在靠近周向末端和顶箔侧;气膜、顶箔和推力盘温度均会随推力盘转速和轴承载荷的增大而升高;向箔片结构中通入冷却气流可以获得良好的降温效果,轴承温度随着箔片内通入冷却气流量的增大,先迅速下降后趋于平缓.      

中心裂纹圆盘应力强度因子的测试误差分析

本文在中心裂纹圆盘应力强度因子解析解的基础上,利用一阶微分法则,给出了与裂纹相对长度和加载角相关的应力强度因子(K 和K )的4个误差传递函数。这4个误差传递函数关于裂纹相对长度和加载角均是非线性的,它们既是误差分析的基础,又是合理确定裂纹相对长度和加载角的基础。分析结果表明,加载角的误差Δθ除了对纯 型K 的误差几乎没有影响,对纯 型K 影响较小外,对复合型K 、K 的误差均有较大影响。最后,本文建议裂纹相对长度的取值范围为0.4～0.6;还建议在复合型断裂试验时,必须依据对K 、K 的总体精度要求来严格控制加载角的精度。     

The Potential for Assessing Residual Stress Using Thermoelastic Stress Analysis: A Study of Cold Expanded Holes

Thermoelastic stress analysis (TSA) is a well established tool for non-destructive full-field experimental stress analysis. In TSA the change in the sum of the principal stresses is derived, usually when a component is subjected to a cyclic load. Therefore the mean stress or any residual stress in a component cannot be obtained from the thermoelastic response. However, modifications to the linear form of the thermoelastic equation that incorporate the mean stress may provide a means of establishing the residual stresses. It has also been shown that the application of plastic strain modifies the thermoelastic constant in some materials, causing a change in thermoelastic response, which may also be related to the residual stress. The changes in response due to plastic strain and mean stress are of the order of a few mK and are significantly less than those expected to be resolved in standard TSA. Recent developments in infra-red detector technology have enabled these small variations in the thermoelastic response to be identified, leading to renewed interest in the use of TSA for residual stress analysis in realistic components. The component studied in this work is an aluminium plate that contains a cold expanded hole, hence providing an opportunity to examine any changes in thermoelastic response caused by the residual stress in the neighbourhood of the hole. The variations in thermoelastic response due to residual stress are shown to be measurable and significant; validation of the residual stress field is provided by laboratory X-ray diffraction. The potential for a TSA based approach for residual stress analysis is revisited, and the feasibility of applying it to components containing realistic residual stress levels is assessed.     

深层地下地应力测量

介绍了对某水力压裂法处置中放废液工程进行的深层地下地应力测量的有关情况。利用压阻型压力传感器和压力盒相结合的办法克服压力探头敏感面小带来的测量困难 ,成功进行了地下数百米深度处地应力测量。实际测量表明系统工作可靠 ,测量数据可信。