MODIFIED LAYER REMOVAL METHOD FOR MEASUREMENT OF RESIDUAL STRESS DISTRIBUTION IN THICK PRE-STRETCHED ALUMINUM PLATE

The integrated structure parts are widely used in aircraft. The distortion caused by residual stresses in thick pre-stretched aluminum plates during machining integrated parts is a common and serious problem. To predict and control the machining distortion, the residual stress distribution in the thick plate must be measured firstly. The modified removal method for measuring residual stress in thick pre-stretched aluminum plates is proposed and the stress-strain relation matrix is deduced by elasticity theory. The residual stress distribution in specimen of 7050T7451 plate is measured by using the method, and measurement results are analyzed and compared with data obtained by other methods. The method is effective to measure the residual stress.

Three-Dimensional Thermo-Elastic-Plastic Finite Element Method Modeling for Predicting Weld-Induced Residual Stresses and Distortions in Steel Stiffened-Plate Structures

The objective of the present paper is to develop nonlinear finite element method models for predicting the weld-induced initial deflection and residual stress of plating in steel stiffened-plate structures. For this purpose, three-dimensional thermo-elastic-plastic finite element method computations are performed with varying plate thickness and weld bead length (leg length) in welded plate panels, the latter being associated with weld heat input. The finite element models are verified by a comparison with experimental database which was obtained by the authors in separate studies with full scale measurements. It is concluded that the nonlinear finite element method models developed in the present paper are very accurate in terms of predicting the weld-induced initial imperfections of steel stiffened plate structures. Details of the numerical computations together with test database are documented.

A review of welding residual stress test methods

Due to local uneven heating during the welding process,the residual stress of the structure after welding affects the reliability of it.In order to ensure the reliability,it is of great significance to test the residual stress distribution of the welded joint.It has always been the focus to find a simple and feasible method for residual stress testing to quickly and accurately obtain the residual stress distribution of welded joints.The mechanical measurement method has high measurement accuracy,convenient and easy operation,but it will cause certain damage to the components.Physical measurement method can avoid damage to components,but its test cost is usually high,and its measurement accuracy can also be affected by the material microstructure characteristics of welded components.Based on the advantages and disadvantages of these two residual stress test methods,a modal test method is proposed.This method is a non-destructive measurement method.Based on the mathematical relationship between the residual stress of the welded structure and the natural frequency(mathematical model),the natural frequency is measured through the modal test to calculate the residual stress quickly.However,it is difficult to establish a mathematical model with this method,and it is not suitable for realization.

TECHNOLOGY OF QUANTITATIVE ANALYSIS ON VIBRATORY STRESS RELIEF BASED ON ULTRASONIC TIME-OF-ARRIVAL METHOD

The effect of vibratory stress relief （VSR） is usually evaluated with the indirect method of observing the change of amplitude frequency response characteristics of structures. A new kind of evaluating method of VSR based on the ultrasonic time-of-arrival method （UTM）, which can obtain the residual stress directly through measuring the propagation time of ultrasonic wave in the material, is presented. At first, the principle of the measuring method of residual stress based on UTM is analyzed. Then the measuring system of the method is described, which is in virtue of ultrasonic flaw detector and high-sampling-rate digital oscillograph. And a set of calibration system that contains a piece of standard specimen is also introduced. Experimental results prove the relation between the residual stress and the propagation time of ultrasonic in workpieces. Finally, the measuring and calibration systems are applied in evaluating the effect of VSR. The final test results show that the method is effective.

A review on stress determination and control in metal-based additive manufacturing

Metal additive manufacturing(MAM)is an emerging and disruptive technology that builds three-dimensional(3D)components by adding layer-upon-layer of metallic materials.The complex cyclic thermal history and highly localized energy can produce large temperature gradients,which will,in turn,lead to compressive and tensile stress during the MAM process and eventually result in residual stress.Being an issue of great concern,residual stress,which can cause distortion,delamination,cracking,etc.,is considered a key mechanical quantity that affects the manufacturing quality and service performance of MAM parts.In this review paper,the ongoing work in the field of residual stress determination and control for MAM is described with a particular emphasis on the experimental measurement/control methods and numerical models.We also provide insight on what still requires to be achieved and the research opportunities and challenges.

超深勘察钻孔ASR法地应力测试技术应用

宝灵山隧道是某铁路先开段的重难点控制性工程,其中宝灵山DZ-06勘察钻孔深2118.00 m,是该段深度最大的控制性勘察钻孔。在钻孔的2072.53、2084.27 m深度选取合适岩心,采用ASR法(非弹性应变恢复法)开展了地应力测试,并与该钻孔采用水压致裂法获取的地应力结果进行对比,同时验证了ASR法对于估测超深钻孔的三维地应力大小和方向的实用价值。结果表明:在钻孔2072.53~2084.27 m深度范围,ASR法2个测点获取的最大主应力、中间主应力、最小主应力平均值分别为59.70、54.03、30.74 MPa,最大主应力近水平,方向近SN向,说明该区域以水平构造应力为主;ASR法的最大主应力测试结果均值与水压致裂法测试结果回归值一致性很好,最小主应力测试结果均值与水压致裂法测试结果回归值的一致性处于合理范围,两种方法的水平主应力方向测试结果基本一致。

残余应力检测技术及其应用

随着我国工业水平的不断提升,残余应力问题日益受到重视。准确测试和控制残余应力可以实现改善材料性能、提升尺寸精度、延长寿命等目的,进而提升关键工程构件的安全性和可靠性。因此,残余应力检测技术在航空航天、核电、船舶等领域发挥着重要作用,为工程构件力学性能研究和安全评估提供关键数据支持。总结了目前常用的残余应力检测技术的原理、适用范围、优缺点等,讨论了选择残余应力检测技术时需考虑的主要因素,指出了残余应力检测技术在科研和应用领域的发展趋势。

波形钢腹板工字形梁焊接残余应力研究

采用数值模拟与试验的方法对Q345钢波形钢腹板工字形梁焊接温度场与残余应力分布进行了研究.采用完全耦合法建立了波形钢腹板工字形梁热弹塑性三维有限元模型,得到其焊接温度场与应力场,并通过在有限元模型中定义多条研究路径的方法,研究了不同路径上纵、横向焊接残余应力的分布规律.在波形钢腹板工字形梁的焊接过程中采用红外线测温法与电阻应变计法进行焊接温度与残余应力的试验研究.结果表明:焊接残余应力的数值模拟结果与实测结果吻合较好,验证了数值模拟方法的正确性和可行性;焊接过程中热源中心稳定温度高达1401℃,远离热源中心温度迅速降低,当与热源中心距离大于25 cm时温度已趋近室温;波形钢腹板弯折角处焊缝的最大Von Mises应力为395 MPa,远高于材料的屈服强度;腹板表面距焊缝0.5 cm处的纵向残余应力高达351 MPa,而波形钢腹板表面的横向残余应力呈抛物线形式波动,最大值为48.5 MPa;波形钢腹板工字形梁上的焊接残余应力以纵向应力为主,且主要分布于距焊缝20 cm的范围内.研究结论可为实际工程中波形钢腹板工字形梁的残余应力消除提供参考依据.

Residual Stress Measurement in Electron Beam Welded Joints of 50mm Thick Titanium Alloy

For researching the residual stress distribution characteristics of the different large thickness titanium alloy joints by electron beam welding,under heat treatment or non-heat treatment conditions,the changes in residual stress distribution characteristics of electron beam welding joints,which thickness is 50 mm,were measured using blind-hole method with local layer-by-layer removal.Effect of post-welding heat treatment on the residual stress distribution also studied.The results show that blind-hole method with local layer-by-layer removal is suitable to measure residual stresses in thick plate,and good to reflect the welded residual stress distribution of large gradient.Residual stress of the test samples in the weld and heat affected zone has high stress level,and internal stress dramatic changes with thickness in this areas.After heat treatment,the samples' stress distributions were significantly reduced.The samples' transverse and longitudinal residual stress are basically the same.Homogenization is obvious.

X射线法测量多晶材料残余应力

简要介绍了机械工件(或构件)的残余应力的来源及其对机械工件使用寿命的影响。概述了晶体残余应力测量中的有损检测和无损测量各自所包括的具体测量方法以及各测量方法的特点和适用情况。重点阐述了X射线法测量残余应力的基本原理、特点和测量时应注意的问题。

残余应力物理法测量技术研究状况

简要回顾了残余应力的分类及测量方法,介绍了X射线法、中子衍射法、超声波法和磁性法等物理法测量残余应力的原理、特点及国内外应用情况。对比分析了各种物理法测残余应力的优缺点,对选择物理法进行残余应力测试具有一定的指导意义。

涂层残余应力实用检测技术的研究进展

针对常用的金属材料涂层,综述了当前一些可行的检测金属涂层中残余应力的方法,重点阐述了弯曲法、钻孔法、X射线衍射法、中子衍射法和喇曼光谱法的基本原理及应用情况。

一种测定深部岩体地应力的新方法——钻孔局部壁面应力全解除法

简要回顾了基于钻孔进行地应力测量的几种方法,并指出了这些方法自身存在的局限性。提出了一种测定深部岩体地应力的新方法——钻孔局部壁面应力全解除法。该方法的明显优点是,不需要套钻,而且在确定地应力的主值及其方向时也不需要作任何假定。从理论上讲,该方法将不受测量深度的限制,对于深钻孔是普遍适用的,这将为大陆科学钻探计划中深部岩体地应力测量提供一种新途径。

中国大陆科学钻探主孔声发射法现今地应力状态的确定

对中国大陆科学钻探主孔的岩心进行了声发射测量,确定了301～1531m深度的最大主应力。并与钻孔崩落法(深度1269～1655m)测量结果进行了对比,结果表明,声发射测量所得测值基本上落在钻孔崩落法测值的趋势线上,两种方法所得结果一致,说明测量结果可信。测量结果表明科学钻探主孔地应力大小随深度增加,在浅部301m最大主应力为13.4MPa,在深部1655m为55.2MPa。随深度的增加率为0.0279MPa/m。最大主应力方向为N54°±3.3°E,且方向不随深度变化。

预拉伸铝合金厚板7050T7451内部残余应力分布测试理论及试验研究

根据预拉伸铝合金厚板的特点,运用弹性力学理论推导出厚板内部残余应力测量的新方法.用此方法测量了预拉伸铝合金厚板7050T7451沿厚度方向的残余应力分布,并对测试结果进行了分析.结果表明,本文推导出的新方法测量厚板内部残余应力简单、精确,有很强的工程实用性.

残余应力测试方法的研究进展

综述了测量残余应力的方法,主要有机械释放法和非破坏性无损伤测量法以及消除残余应力的方法,并提出合理的选择。

残余应力测量研究现状综述

针对残余应力测量的重要性,对其测量方法进行综述和展望。阐述传统的残余应力测量方法的原理及应用情况,包括传统机械释放法和非破坏性无损伤测量法;主要介绍几种新型的残余应力测量方法及其原理;并指出残余应力的测量技术正朝着无损、在线测量、绿色等方向发展。

基于轮廓法测试焊接件内部残余应力

采用轮廓法测试低碳钢堆焊件和T形焊接结构的内部纵向残余应力。将焊接件沿垂直焊缝平面切割开,精确测试切割面的变形轮廓,然后将测试轮廓进行拟合,并将拟合结果作为有限元模型的边界条件进行弹性计算从而获得内部垂直切割平面的应力分布。比较不同曲面拟合方法拟合得到的切割面轮廓形貌;将轮廓法测试的焊接残余应力结果和热弹塑性三维有限元计算结果进行比较分析。研究结果表明:轮廓法能准确高效测试较厚焊接件内部整个截面上的纵向应力分布;由于线切割和轮廓测量误差造成轮廓法测得的应力在约2 mm厚表层区域的幅值和有限元计算结果相比误差较大,但轮廓法测试结果仍能反映出表层应力的分布趋势和特征;线切割断丝造成切割面的局部轮廓误差,会引起断丝区域测试应力出现突变。

T型焊接试件焊接残余应力分布的测定

为了掌握钢结构中焊接残余应力的具体分布状态,采用基于逆磁致伸缩效应原理的无损检测方法,利用磁测应力仪对T型焊接试件焊缝附近不同层深处的焊接残余应力进行了实际测量,得到了距焊件表面1、1.5和2 mm三个不同层深的焊接残余应力分布规律,并和基于有限元法的数值模拟计算结果进行了对比分析。结果表明,焊缝附近区域残余应力较大,随着层深的增加,横向和纵向残余应力均由压应力逐渐过渡为拉应力,而纵向残余应力在远离焊缝中心的区域内,则改由拉应力过渡为压应力。

陶瓷磨削表面残余应力测试方法的研究

用研磨抛光法与连续腐蚀法测试陶瓷磨削表面残余应力 ,与 X射线衍射法相比较 ,具有经济、简便、测试精度高的优点。在避免了应变信号的不稳定性与附加应力的条件下 ,对于非金属氧化物陶瓷来说 ,这两种方法完全可以取代