Effect of quenching cooling rate on residual stress and microstructure evolution of 6061 aluminum alloy

In this study,the cooling rate was manipulated by quenching with water of different temperatures(30,60 and 100℃).Surface and internal residual stresses in the quenched 6061 aluminum alloy samples were measured using hole-drilling and crack compliance methods,respectively.Then,the processability of the quenched samples was evaluated at cryogenic temperatures.The mechanical properties of the as-aged samples were assessed,and microstructure evolution was analyzed.The surface residual stresses of samples W30℃,W60℃and W100℃is−178.7,−161.7 and−117.2 MPa,respectively along x-direction,respectively;and−191.2,−172.1 and−126.2 MPa,respectively along y-direction.The sample quenched in boiling water displaying the lowest residual stress(~34%and~60%reduction in the surface and core).The generation and distribution of quenching residual stress could be attributed to the lattice distortion gradient.Desirable plasticity was also exhibited in the samples with relatively low quenching cooling rates at cryogenic temperatures.The strengthes of the as-aged samples are 291.2 to 270.1 MPa as the quenching water temperature increase from 30℃to 100℃.Fine and homogeneous β"phases were observed in the as-aged sample quenched with boiling water due to the clusters and Guinier-Preston zones(GP zones)premature precipitated during quenching process.

A modified smoothed particle hydrodynamics method considering residual stress for simulating failure and its application in layered rock mass

Residual strength is an indispensable factor in evaluating rock fracture,yet the current Smoothed Particle Hydrodynamics(SPH)framework rarely considers its influence when simulating fracture.An improved cracking strategy considering residual stress in the base bond SPH method was proposed to simulate failures in layered rocks and slopes and verified by experimental results and other simulation methods(i.e.,the discrete element method).Modified Mohr–Coulomb failure criterion was applied to distinguish the mixed failure of tensile and shear.Bond fracture markψwas introduced to improve the kernel function after tensile damage,and the calculation of residual stress after the damage was derived after shear damage.Numerical simulations were carried out to evaluate its performance under different stress and scale conditions and to verify its effectiveness in realistically reproducing crack initiation and propagation and coalescence,even fracture and separation.The results indicate that the improved cracking strategy precisely captures the fracture and failure pattern in layered rocks and rock slopes.The residual stress of brittle tock is correctly captured by the improved SPH method.The improved SPH method that considers residual strength shows an approximately 13%improvement in accuracy for the safety factor of anti-dip layered slopes compared to the method that does not consider residual strength,as validated against analytical solutions.We infer that the improved SPH method is effective and shows promise for applications to continuous and discontinuous rock masses.

Residual stress modeling of mitigated fused silica damage sites with CO_(2)laser annealing

A numerical model based on measured fictive temperature distributions is explored to evaluate the residual stress fields of CO_(2)laser-annealed mitigated fused silica damage sites.The proposed model extracts the residual strain from the differences in thermoelastic contraction of fused silica with different fictive temperatures from the initial frozen-in temperatures to ambient temperature.The residual stress fields of mitigated damage sites for the CO_(2)laser-annealed case are obtained by a finite element analysis of equilibrium equations and constitutive equations.The simulated results indicate that the proposed model can accurately evaluate the residual stress fields of laser-annealed mitigated damage sites with a complex thermal history.The calculated maximum hoop stress is in good agreement with the reported experimental result.The estimated optical retardance profiles from the calculated radial and hoop stress fields are consistent with the photoelastic measurements.These results provide sufficient evidence to demonstrate the suitability of the proposed model for describing the residual stresses of mitigated fused silica damage sites after CO_(2)laser annealing.

Additive manufacturing of Ni-based superalloys: Residual stress, mechanisms of crack formation and strategies for crack inhibition

The additive manufacturing(AM)of Ni-based superalloys has attracted extensive interest from both academia and industry due to its unique capabilities to fabricate complex and high-performance components for use in high-end industrial systems.However,the intense temperature gradient induced by the rapid heating and cooling processes of AM can generate high levels of residual stress and metastable chemical and structural states,inevitably leading to severe metallurgical defects in Ni-based superalloys.Cracks are the greatest threat to these materials’integrity as they can rapidly propagate and thereby cause sudden and non-predictable failure.Consequently,there is a need for a deeper understanding of residual stress and cracking mechanisms in additively manufactured Ni-based superalloys and ways to potentially prevent cracking,as this knowledge will enable the wider application of these unique materials.To this end,this paper comprehensively reviews the residual stress and the various mechanisms of crack formation in Ni-based superalloys during AM.In addition,several common methods for inhibiting crack formation are presented to assist the research community to develop methods for the fabrication of crack-free additively manufactured components.

Application of Nonlinear Lamb Wave Mixing Method for Residual Stress Measurement in Metal Plate

Harmonic nonlinear ultrasound can offer high sensitivity for residual stress measurements;however,it cannot be used for local stress measurements at a point in space and exhibits nonlinear distortions in the experimental system.This paper presents a feasibility study on the measurement of residual stress in a metal plate using a nonlinear Lamb wave-mixing technique.The resonant conditions for two Lamb waves to generate a mixing frequency wave are obtained via theoretical analysis.Finite element simulations are performed to investigate the nonlinear interactions between the two Lamb waves.Results show that two incident A0 waves interact in regions of material nonlinearity and generate a rightward S0 wave at the sum frequency.Residual stress measurement experiments are conducted on steel plate specimens using the collinear Lamb wave-mixing technique.By setting different delays for two transmitters,the generated sum-frequency component at different spatial locations is measured.Experimental results show that the spatial distribution of the amplitude of the sum-frequency component agrees well with the spatial distribution of the residual stress measured using X-rays.The proposed collinear Lamb wave-mixing method is effective for measuring the distribution of residual stress in metal plates.

Residual stress measurement and analysis of siliceous slate-containing quartz veins

Engineering geological disasters such as rockburst have always been a critical factor affecting the safety of coal mine production.Thus,residual stress is considered a feasible method to explain these geomechanical phenomena.In this study,electron backscatter diffraction(EBSD)and optical microscopy were used to characterize the rock microcosm.A measuring area that met the requirements of X-ray diffraction(XRD)residual stress measurement was determined to account for the mechanism of rock residual stress.Then,the residual stress of a siliceous slate-containing quartz vein was measured and calculated using the sin^(2) ϕ method equipped with an X-ray diffractometer.Analysis of microscopic test results showed homogeneous areas with small particles within the millimeter range,meeting the requirements of XRD stress measurement statistics.Quartz was determined as the calibration mineral for slate samples containing quartz veins.The diffraction patterns of the(324)crystal plane were obtained under different ϕ and φ.The deviation direction of the diffraction peaks was consistent,indicating that the sample tested had residual stress.In addition,the principal residual stress within the quartz vein measured by XRD was compressive,ranging from 10 to 33 MPa.The maximum principal stress was parallel to the vein trend,whereas the minimum principal stress was perpendicular to the vein trend.Furthermore,the content of the low-angle boundary and twin boundary in the quartz veins was relatively high,which enhances the resistance of the rock mass to deformation and promotes the easy formation of strain concentrations,thereby resulting in residual stress.The proposed method for measuring residual stress can serve as a reference for subsequent observation and related research on residual stress in different types of rocks.

Residual stress with asymmetric spray quenching for thick aluminum alloy plates

Solution and quenching heat treatments are generally carried out in a roller hearth furnace for large-scale thick aluminum alloy plates.However,the asymmetric or uneven spray water flow rate is inevitable under industrial production conditions,which leads to an asymmetric residual stress distribution.The spray quenching treatment was conducted on self-designed spray equipment,and the residual stress along the thickness direction was measured by a layer removal method based on deflections.Under the asymmetric spray quenching condition,the subsurface stress of the high-flow rate surface was lower than that of the low-flow rate surface,and the difference between the two subsurface stresses increased with the increase in the difference in water flow rates.The subsurface stress underneath the surface with a water flow rate of 0.60 m^(3)/h was 15.38 MPa less than that of 0.15 m^(3)/h.The simulated residual stress by finite element(FE)method of the high heat transfer coefficient(HTC)surface was less than that of the low HTC surface,which is consistent with the experimental results.The FE model can be used to analyze the strain and stress evolution and predict the quenched stress magnitude and distribution.

Study of residual stresses and distortions from the Ti6Al4V based thinwalled geometries built using LPBF process

The current paper focuses on the prediction of residual stresses and distortions in the Laser Powder Bed Fusion(LPBF)built Ti6Al4V thin-walled geometries using Ansys Additive Print(AAP)software which employs a layer-by-layer accumulation of inherent strain to calculate the deformations.Isotropic and anisotropic strain scaling factors were calibrated initially within the APP software for the Ti6Al4V based single cantilever beam geometry.Subsequently,the numerical simulations were performed in APP software and computed the residual stresses and distortions for the varied process parameters including laser power,scan speed and hatch distance while maintaining the layer thickness constant for all the design iterations.The numerical predictions were compared;they were found to match reasonably well with the XRD measurements within the calibrated regime.

Residual Stress Distribution of Si_(3)N_(4)/SiC Gradient Material and the Effect of Residual Stress on Material Properties

The Si_(3)N_(4)/SiC gradient material with a gradient composition structure was prepared by a hot pressing sintering.The sinterability,distribution of residual stress and the effect of residual stress on mechanical properties of Si_(3)N_(4)/SiC gradient materials were studied.The research results show that,at 1750℃,Si_(3)N_(4)/SiC gradient materials with different ratios can achieve co-sintering,and the overall relative density of the sample reaches 98.5%.Interestingly,the flexural strength of Si_(3)N_(4)/SiC gradient material is related to its loading surface.The flexural strength of SiC as the loading surface is about 35%higher than that of Si_(3)N_(4)as the loading surface.The analysis of the residual stress of the material in the gradient structure shows that the gradient stress distribution between the two phases is a vital factor affecting the mechanical properties of the material.With the increase of SiC content in the gradient direction,the fracture toughness of each layer of Si_(3)N_(4)/SiC gradient materials gradually decreases.The surface hardness of the pure SiC side is lower than that reported in other literature.

Residual Stresses and Forming Quality of Metal Bipolar Plates for PEMFC During the Stamping Process

Stamping is a critical step in the manufacture of metallic bipolar plates.Typically,residual stress and a spring back effect appear on the bipolar plate after the stamping process,which impacts on the performance and lifetime of the proton exchange membrane fuel cell(PEMFC).The residual stress and spring back behavior which occur as a result of stamping a bipolar plate are investigated in this study.The effects of the punch radius,the die radius,the channel depth,and the clearance between the punch and the die on the residual stress and forming quality of the bipolar plate are examined.The stamping process can be divided into three stages.The high stress area and the middle section residual stress area were selected to study the formation process and to obtain the composition of the residual stress regions.Spring back was mainly related to the position of the fixed end of the sheet and the degree of plastic deformation,and the sheet thickness have increased by 2μm after spring back.Based on the results of finite element analysis,as described by the distribution of residual stress,the formation,the thickness of the middle cross section and the equivalent plastic strain,it was found that all the tool parameters affected the distribution of the residual stress.This research can provide a design reference for the manufacture of metallic bipolar plates based on the stamping process.

Mechanism investigation and strategies for reducing residual stress at open ends of the roll-formed part

Increasing geometrical accuracy at open ends of the roll-formed part is difficult due to the release of residual stress after end cutting.In this work,a typical rail with a high requirement of geometry accuracy was selected to realize the behaviors of residual stress release.First,residual stress distribution after roll forming is discussed in detail by finite element analysis with ABAQUS.In addition,two different approaches are proposed to check their capabilities in reducing the residual stress level.The results indicate that both additional rolling passes and multiple bending processes are beneficial to reducing uniform residual stress.

Effect of welding sequence on residual stress in thin-walled octagonal pipe-plate structure

A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To obtain sound numerical results, the therrno-mechanical behaviour was simulated using a direct-coupled formulation. Nine different simulation sequences were carried out by single-pass TIG welding of an octagonal pipe-plate joint, and the distributions of longitudinal and transverse residual stresses both on the outer and inner surfaces of the pipe were analyzed. The results suggest that the final residual stresses in the weld and its vicinity are not affected by the initial residual stresses of the structure. Selecting a suitable welding sequence can reduce the final residual stress in an octagonal pipe-plate joint.

A Way to Determine the Maximum Inducible Residual Stresses in Steel by Mechanical Surface Treatment

The issue of determining the maximum compressive residual stress that can be induced through mechanical surface treatment is of great significance.There are two possible approaches,namely stress peening and stress rolling,both to determine the limit.Steel with high hardness may be under the yield strength,while for those with lower tensile strength,the hardness is increased,and the limit is above the tensile strength.

Residual Stress and Fracture Toughness Study in A516 Gr70 Steel Joints Welded and Repaired by Arc Processes

Structural components made of steel are used in several areas and require welding for assembly. In some situations, repair of the weld bead, also performed by electric arc welding, can be used to correct, and eliminate any discontinuities. However, electric arc welding causes the presence of residual stresses in the joint, which can impair its performance and not meet specific design requirements. In this paper, welded joints made of ASTM A 516 GR 70 steel plates, with a thickness of 30.5 mm, welded by the MAG—Metal Active Gas process (20% CO2) and using a “K” groove were analysed. The joints were manufactured with seven welding passes on each side of the groove. After welding, one batch underwent repair of the bead by TIG welding (Tungsten Insert Gas) and another batch underwent two repairs by TIG welding. Were presented results of the behaviour of the residual stress profile measured by X-ray diffraction and the Vickers microhardness profile in the joints as well the fracture toughness in the conditions only welded and submitted to repairs. The results indicated that the greater number of repair passes reduced the residual compressive stress values obtained in the material manufacturing process and caused a stabilization on the Vickers hardness values. It was concluded that compressive residual stresses did not play a major role in the R-curve results. The presence of discontinuities in the welded joint caused greater influence on the behaviour of the R curve.

Literature Review of Electronic Packaging Technology and Residual Stress

The rapid development of the electronic information industry brings to the irreplaceable role of electronic components, therefore the search of a more reliable packaging material has become increasingly important. In the electronic packaging system, the failure phenomenon caused by residual stress is one of the key factors restricting the development of electronic packaging technology. In order to use the in-situ characterization technology to explore the residual stress inducing mechanism and failure mechanism of epoxy-based advanced packaging materials, this paper gives a review of related previous research, and lays a theoretical foundation for the upcoming research. The classification and generation mechanism of residual stress are clarified in this paper, which provides data support for future related research.

Fatigue Life Prediction for SiC/Al Materials Based on Path Planning Algorithm Considering Residual Stress

To explore the influence of path deflection on crack propagation,a path planning algorithm is presented to calculate the crack growth length.The fatigue crack growth life of metal matrix composites(MMCs)is estimated based on an improved Paris formula.Considering the different expansion coefficient of different materials,the unequal shrinkage will lead to residual stress when the composite is molded and cooled.The crack growth model is improved by the modified stress ratio based on residual stress.The Dijkstra algorithm is introduced to avoid the cracks passing through the strengthening base and the characteristics of crack steps.This model can be extended to predict crack growth length for other similarly-structured composite materials.The shortest path of crack growth is simulated by using path planning algorithm,and the fatigue life of composites is calculated based on the shortest path and improved model.And the residual stress caused by temperature change is considered to improve the fatigue crack growth model in the material.The improved model can well predict the fatigue life curve of composites.By analyzing the fatigue life of composites,it is found that there is a certain regularity based on metal materials,and the new fatigue prediction model can also reflect this regularity.

Evaluation on residual stresses of silicon-doped CVD diamond films using X-ray diffraction and Raman spectroscopy

The effect of silicon doping on the residual stress of CVD diamond films is examined using both X-ray diffraction (XRD) analysis and Raman spectroscopy measurements. The examined Si-doped diamond films are deposited on WC-Co substrates in a home-made bias-enhanced HFCVD apparatus. Ethyl silicate (Si(OC2H5)4) is dissolved in acetone to obtain various Si/C mole ratio ranging from 0.1% to 1.4% in the reaction gas. Characterizations with SEM and XRD indicate increasing silicon concentration may result in grain size decreasing and diamond [110] texture becoming dominant. The residual stress values of as-deposited Si-doped diamond films are evaluated by both sin2ψ method, which measures the (220) diamond Bragg diffraction peaks using XRD, with ψ-values ranging from 0° to 45°, and Raman spectroscopy, which detects the diamond Raman peak shift from the natural diamond line at 1332 cm-1. The residual stress evolution on the silicon doping level estimated from the above two methods presents rather good agreements, exhibiting that all deposited Si-doped diamond films present compressive stress and the sample with Si/C mole ratio of 0.1% possesses the largest residual stress of ~1.75 GPa (Raman) or ~2.3 GPa (XRD). As the silicon doping level is up further, the residual stress reduces to a relative stable value around 1.3 GPa.

An Overview of Techniques for Measuring Residual Stress in Metal Matrix Composites

Measurement of residual stress is significant to ensure safety, reliability and the life of composites, and currently has been a hot issue in scientific research. The fabrication processes such as machining, and heat treatment inherit either kind of residual stress which had either positive consequences or negative ones, for example, the fatigue limit of a component enhances by compressive stress, whereas corrosion resistance gets reduced by tensile stress. This study is aimed at a brief overview of the recent advancement in this field to help researchers in the in-depth study of measuring residual stress. It helps them in selecting the most appropriate techniques among destructive methods i.e., mainly Contour, ring core, deep hole-drilling method, and non-destructive techniques i.e., diffraction, ultrasonic method, depending on their requirements and applications. For each available technique, working methodology, physical limitations, and applications are discussed. At the end of this paper, future trends regarding an assessment of residual stress have been forecasted.

Internal residual stress measurement on linear friction welding of titanium alloy plates with contour method

The internal residual stress within a TC 17 titanium alloy joint welded by linear friction welding （LFW） was measured by the contour method, which is a relatively new and destructive technique to obtain a full map of internal residual stress. The specimen was first cut into two parts; the out-of-plane displacement contour formed by the release of the residual stress was then measured; finally, taking the measured contour of the cut plane as the boundary conditions, a linear elastic finite element analysis was carried out to calculate the corresponding distribution of residual stress normal to the cut plane. The internal stress distribution of the TC 17 titanium alloy LFWjoint was also analyzed. The results show that the tensile residual stress in the TC17 LFW weld is mainly present within a region about 12 mm from the weld centerline; the peak tensile residual stress occurs at the weld centerline and reaches 360 MPa （about one third of the yield strength of TC17 alloy）; within the weld zone of the TC17 LFW weld, the through-thickness stress is not uniform, and the internal stress is larger than that near the top or bottom surface.

Prediction of vulnerable zones based on residual stress and microstructure in CMT welded aluminum alloy joint

Numerical simulation and experimental results were employed for the identification of the most vulnerable zones in three-pass cold-metal-transferring （CMT） welded joint. The residual stress distribution in the joint was predicted by finite element （FE） method, while the structural morphology of distinctive zones was obtained through metallographic experiments. The highest principal stress made the symmetric face of the joint most sensitive to tensile cracks under service conditions. Whereas, the boundaries between the weld seam and the base plates were sensitive to cracks because the equivalent von Mises stress was the highest when the first interpass cooling was finished. The third weld pass and the inter-pass remelted zones exhibited the modest mechanical performances as a result of the coarse grain and coarse grain boundary, respectively. The most vulnerable zones were regarded to be the crossed parts between the zones identified by numerical and experimental methods.