Application of multiple analysis methods in optimising complex residual stress characterisation

S. Hossain; G. Zheng; C.E. Truman; D.J. Smith

doi:10.1007/s40799-017-0193-2

Application of multiple analysis methods in optimising complex residual stress characterisation

S. Hossain, G. Zheng, C.E. Truman, D.J. Smith

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Abstract

An accurate characterisation of residual stress plays an important role in the structural integrity assessment of an engineering component. Several techniques and tools are available for measuring and predicting residual stresses. For example, neutron diffraction (ND) and X-ray diffraction (XRD) are non-destructive techniques used for measuring through-thickness and surface residual stresses respectively, while the deep-hole drilling (DHD) and the incremental centre-hole drilling (ICHD) are semi-destructive techniques and measure through-thickness and sub-surface residual stress respectively. In most open literature, a more favoured method is traditionally used over others, with some degree of validation using finite element analysis (FEA) predictive tool. In this paper it will be shown that the different methods and tools available are not contradicting or more superior to the others, but rather, the use of more than one available technique complementary to each other can improve the quality and the confidence in the characterisation of the residual stress state in an engineering component. In particular, the accurate knowledge of the residual stress field for a safety critical component plays a vital role for subsequent structural integrity assessment. © 2017, The Author(s).

Original language	English
Pages (from-to)	483-503
Number of pages	21
Journal	Experimental Techniques
Volume	41
Issue number	5
Early online date	12 Jul 2017
DOIs	https://doi.org/10.1007/s40799-017-0193-2
Publication status	Published - Oct 2017

Bibliographical note

Export Date: 13 September 2017

CODEN: EXPTD

Correspondence Address: Hossain, S.; Department of Mechanical Engineering, University of BristolUnited Kingdom; email: [email protected]

References: Albertini, G., Bruno, G., Dunn, B.D., Fiori, F., Reimers, W., Wright, J.S., Comparative neutron and X-ray residual stress measurements on Al-2219 welded plate (1997) Mater Sci Eng A, 224 (1-2), pp. 157-165; (2005) Measurement of residual stress in materials using neutrons. IAEA-TECDOC-1457. IAEA; Kingston, E., (2003) Advances in the deep-hole drilling technique for residual stress measurement, , PhD Thesis: University of Bristol; Robinson, J.S., Hossain, S., Truman, C.E., Oliver, E.C., Hughes, D.J., Fox, M.E., (2008) Influence of cold compression on the residual stresses in 7449 forgings. The Eighth International Conference on Residual Stresses, , Denver, Colorado, USA; Alizadeh, H., Lewis, S.J., Gill, C., Hossain, S., Smith, D.J., Truman, C.E., (2008), Measurement and prediction of the residual stress field in an autogenously welded stainless steel plate. ASME PVP Conference, PVP2008-61341, Chicago, USA; Robinson, J., (2007) COMPACT deliverable report D2a.1.2, Measurement of the heat transfer coefficient during quenching of the aluminium alloy 7449; Smith, M.C., Smith, A.C., (2006) NET bead on plate round robin: comparison of transient thermal prediction and measurements. Review, , British Energy Generation Ltd, Barnwood; Dennis, R., Leggatt, N., Gregg, A., Optimisation of weld modelling techniques, bead-on-plate analysis (2006) Proceedings of ASME PVP2006-ICPVT-, pp. 11-93907; Zheng, G., Development of the deep-hole drilling method for residual stress measurement in metallic welds (2013) PhD Thesis, , University of Bristol, UK; Sen, S., Aksakal, B., Ozel, A., Transient and residual thermal stresses in quenched cylindrical bodies (2000) Int J Mech Sci, 42, pp. 2013-2029; Zheng, G., Hossain, S., Smith, M.C., Smith, D.J., (2014) Residual stress investigation in a stainless steel ring welded circular disc by over-coring deep hole drilling simulation and measurement. Proceedings of the ASME 2014 Pressure Vessels & Piping Conference, Volume 6B: Materials and Fabrication; (2005) ABAQUS/standard user’s manual, 6.6 ed; Rosenthal, D., The theory of moving source of heat and its application to metal treatments (1946) Trans ASME, 68, pp. 849-866; (2007) ABAQUS/standard user’s manual, 6.7 ed; Kingston, E.J., Stefanescu, D., Mahmoudi, A.H., Truman, C.E., Smith, D.J., Novel applications of the deep-hole drilling technique for measuring through-thickness residual stress distributions (2006) J ASTM Int, 3 (4), pp. 1-12; George, D., Kingston, E., Smith, D.J., Measurement of through-thickness stresses using small holes (2002) J Strain Anal, 37 (2), pp. 125-139; Mahmoudi, A.H., Hossain, S., Truman, C.E., Smith, D.J., Pavier, M.J., A new procedure to measure near yield residual stresses using the deep-hole drilling technique (2009) J Exp Mech, 49 (4), pp. 595-604; Fitzpatrick, M.E., Lodini, A., (2003) Analysis of residual stress by diffraction using Neutron and Synchrotron radiation, , Taylor & francis, London; Robinson, J.S., Hossain, S., Truman, C.E., Paradowska, A.M., Hughes, D.J., Wimpory, R.C., Fox, M.E., Residual stress in 7449 aluminium alloy forgings (2010) Mater Sci Eng A, 527, pp. 2603-2612; Hossain, S., (2005) Residual stresses under conditions of high triaxiality, , PhD Thesis, University of Bristol; Hossain, S., Goudar, D.M., Truman, C.E., Smith, D.J., Simulation and measurement of residual stresses in a type 316H stainless steel offset repair in a pipe girth weld (2011) Mater Sci Forum, 681, pp. 492-497; Pirling, T., Bruno, G., Withers, P.J., SALSA - a new instrument for strain imaging in engineering materials and components (2006) Mater Sci Eng A, 437 (1), pp. 139-144; Hughes, D.J., Bruno, G., Pirling, T., Withers, P.J., Scientific Review: First Impressions of SALSA: The New Engineering Instrument at ILL (2006) Neutron News, 17 (3), pp. 28-320; Garcia Granada, A.A., George, D., Smith, D.J., (1998) Assessment of distortions in the deep-hole technique for measuring residual stress. In: Proceedings of the 11th Conference on Experimental Mechanics, Oxford, pp 1301–1306

Keywords

autogenous welding
conventional and modified deep-hole drilling
finite element simulation
neutron diffraction
quenching
Residual stress
Characterization
Neutron diffraction
Nondestructive examination
Quenching
Residual stresses
Safety engineering
Structural integrity
X ray diffraction
Deep hole drilling
Destructive techniques
Finite element simulations
Incremental centre hole drillings
Non-destructive technique
Safety critical components
Structural integrity assessment
Surface residual stress
Finite element method

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10.1007/s40799-017-0193-2

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@article{09900227cb504027a1559d8f3c606acb,

title = "Application of multiple analysis methods in optimising complex residual stress characterisation",

abstract = "An accurate characterisation of residual stress plays an important role in the structural integrity assessment of an engineering component. Several techniques and tools are available for measuring and predicting residual stresses. For example, neutron diffraction (ND) and X-ray diffraction (XRD) are non-destructive techniques used for measuring through-thickness and surface residual stresses respectively, while the deep-hole drilling (DHD) and the incremental centre-hole drilling (ICHD) are semi-destructive techniques and measure through-thickness and sub-surface residual stress respectively. In most open literature, a more favoured method is traditionally used over others, with some degree of validation using finite element analysis (FEA) predictive tool. In this paper it will be shown that the different methods and tools available are not contradicting or more superior to the others, but rather, the use of more than one available technique complementary to each other can improve the quality and the confidence in the characterisation of the residual stress state in an engineering component. In particular, the accurate knowledge of the residual stress field for a safety critical component plays a vital role for subsequent structural integrity assessment. {\textcopyright} 2017, The Author(s).",

keywords = "autogenous welding, conventional and modified deep-hole drilling, finite element simulation, neutron diffraction, quenching, Residual stress, Characterization, Neutron diffraction, Nondestructive examination, Quenching, Residual stresses, Safety engineering, Structural integrity, X ray diffraction, Deep hole drilling, Destructive techniques, Finite element simulations, Incremental centre hole drillings, Non-destructive technique, Safety critical components, Structural integrity assessment, Surface residual stress, Finite element method",

author = "S. Hossain and G. Zheng and C.E. Truman and D.J. Smith",

note = "Export Date: 13 September 2017 CODEN: EXPTD Correspondence Address: Hossain, S.; Department of Mechanical Engineering, University of BristolUnited Kingdom; email: [email protected] References: Albertini, G., Bruno, G., Dunn, B.D., Fiori, F., Reimers, W., Wright, J.S., Comparative neutron and X-ray residual stress measurements on Al-2219 welded plate (1997) Mater Sci Eng A, 224 (1-2), pp. 157-165; (2005) Measurement of residual stress in materials using neutrons. IAEA-TECDOC-1457. IAEA; Kingston, E., (2003) Advances in the deep-hole drilling technique for residual stress measurement, , PhD Thesis: University of Bristol; Robinson, J.S., Hossain, S., Truman, C.E., Oliver, E.C., Hughes, D.J., Fox, M.E., (2008) Influence of cold compression on the residual stresses in 7449 forgings. The Eighth International Conference on Residual Stresses, , Denver, Colorado, USA; Alizadeh, H., Lewis, S.J., Gill, C., Hossain, S., Smith, D.J., Truman, C.E., (2008), Measurement and prediction of the residual stress field in an autogenously welded stainless steel plate. ASME PVP Conference, PVP2008-61341, Chicago, USA; Robinson, J., (2007) COMPACT deliverable report D2a.1.2, Measurement of the heat transfer coefficient during quenching of the aluminium alloy 7449; Smith, M.C., Smith, A.C., (2006) NET bead on plate round robin: comparison of transient thermal prediction and measurements. Review, , British Energy Generation Ltd, Barnwood; Dennis, R., Leggatt, N., Gregg, A., Optimisation of weld modelling techniques, bead-on-plate analysis (2006) Proceedings of ASME PVP2006-ICPVT-, pp. 11-93907; Zheng, G., Development of the deep-hole drilling method for residual stress measurement in metallic welds (2013) PhD Thesis, , University of Bristol, UK; Sen, S., Aksakal, B., Ozel, A., Transient and residual thermal stresses in quenched cylindrical bodies (2000) Int J Mech Sci, 42, pp. 2013-2029; Zheng, G., Hossain, S., Smith, M.C., Smith, D.J., (2014) Residual stress investigation in a stainless steel ring welded circular disc by over-coring deep hole drilling simulation and measurement. Proceedings of the ASME 2014 Pressure Vessels & Piping Conference, Volume 6B: Materials and Fabrication; (2005) ABAQUS/standard user{\textquoteright}s manual, 6.6 ed; Rosenthal, D., The theory of moving source of heat and its application to metal treatments (1946) Trans ASME, 68, pp. 849-866; (2007) ABAQUS/standard user{\textquoteright}s manual, 6.7 ed; Kingston, E.J., Stefanescu, D., Mahmoudi, A.H., Truman, C.E., Smith, D.J., Novel applications of the deep-hole drilling technique for measuring through-thickness residual stress distributions (2006) J ASTM Int, 3 (4), pp. 1-12; George, D., Kingston, E., Smith, D.J., Measurement of through-thickness stresses using small holes (2002) J Strain Anal, 37 (2), pp. 125-139; Mahmoudi, A.H., Hossain, S., Truman, C.E., Smith, D.J., Pavier, M.J., A new procedure to measure near yield residual stresses using the deep-hole drilling technique (2009) J Exp Mech, 49 (4), pp. 595-604; Fitzpatrick, M.E., Lodini, A., (2003) Analysis of residual stress by diffraction using Neutron and Synchrotron radiation, , Taylor & francis, London; Robinson, J.S., Hossain, S., Truman, C.E., Paradowska, A.M., Hughes, D.J., Wimpory, R.C., Fox, M.E., Residual stress in 7449 aluminium alloy forgings (2010) Mater Sci Eng A, 527, pp. 2603-2612; Hossain, S., (2005) Residual stresses under conditions of high triaxiality, , PhD Thesis, University of Bristol; Hossain, S., Goudar, D.M., Truman, C.E., Smith, D.J., Simulation and measurement of residual stresses in a type 316H stainless steel offset repair in a pipe girth weld (2011) Mater Sci Forum, 681, pp. 492-497; Pirling, T., Bruno, G., Withers, P.J., SALSA - a new instrument for strain imaging in engineering materials and components (2006) Mater Sci Eng A, 437 (1), pp. 139-144; Hughes, D.J., Bruno, G., Pirling, T., Withers, P.J., Scientific Review: First Impressions of SALSA: The New Engineering Instrument at ILL (2006) Neutron News, 17 (3), pp. 28-320; Garcia Granada, A.A., George, D., Smith, D.J., (1998) Assessment of distortions in the deep-hole technique for measuring residual stress. In: Proceedings of the 11th Conference on Experimental Mechanics, Oxford, pp 1301–1306",

year = "2017",

month = oct,

doi = "10.1007/s40799-017-0193-2",

language = "English",

volume = "41",

pages = "483--503",

journal = "Experimental Techniques",

issn = "0732-8818",

publisher = "Springer Verlag",

number = "5",

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TY - JOUR

T1 - Application of multiple analysis methods in optimising complex residual stress characterisation

AU - Hossain, S.

AU - Zheng, G.

AU - Truman, C.E.

AU - Smith, D.J.

N1 - Export Date: 13 September 2017 CODEN: EXPTD Correspondence Address: Hossain, S.; Department of Mechanical Engineering, University of BristolUnited Kingdom; email: [email protected] References: Albertini, G., Bruno, G., Dunn, B.D., Fiori, F., Reimers, W., Wright, J.S., Comparative neutron and X-ray residual stress measurements on Al-2219 welded plate (1997) Mater Sci Eng A, 224 (1-2), pp. 157-165; (2005) Measurement of residual stress in materials using neutrons. IAEA-TECDOC-1457. IAEA; Kingston, E., (2003) Advances in the deep-hole drilling technique for residual stress measurement, , PhD Thesis: University of Bristol; Robinson, J.S., Hossain, S., Truman, C.E., Oliver, E.C., Hughes, D.J., Fox, M.E., (2008) Influence of cold compression on the residual stresses in 7449 forgings. The Eighth International Conference on Residual Stresses, , Denver, Colorado, USA; Alizadeh, H., Lewis, S.J., Gill, C., Hossain, S., Smith, D.J., Truman, C.E., (2008), Measurement and prediction of the residual stress field in an autogenously welded stainless steel plate. ASME PVP Conference, PVP2008-61341, Chicago, USA; Robinson, J., (2007) COMPACT deliverable report D2a.1.2, Measurement of the heat transfer coefficient during quenching of the aluminium alloy 7449; Smith, M.C., Smith, A.C., (2006) NET bead on plate round robin: comparison of transient thermal prediction and measurements. Review, , British Energy Generation Ltd, Barnwood; Dennis, R., Leggatt, N., Gregg, A., Optimisation of weld modelling techniques, bead-on-plate analysis (2006) Proceedings of ASME PVP2006-ICPVT-, pp. 11-93907; Zheng, G., Development of the deep-hole drilling method for residual stress measurement in metallic welds (2013) PhD Thesis, , University of Bristol, UK; Sen, S., Aksakal, B., Ozel, A., Transient and residual thermal stresses in quenched cylindrical bodies (2000) Int J Mech Sci, 42, pp. 2013-2029; Zheng, G., Hossain, S., Smith, M.C., Smith, D.J., (2014) Residual stress investigation in a stainless steel ring welded circular disc by over-coring deep hole drilling simulation and measurement. Proceedings of the ASME 2014 Pressure Vessels & Piping Conference, Volume 6B: Materials and Fabrication; (2005) ABAQUS/standard user’s manual, 6.6 ed; Rosenthal, D., The theory of moving source of heat and its application to metal treatments (1946) Trans ASME, 68, pp. 849-866; (2007) ABAQUS/standard user’s manual, 6.7 ed; Kingston, E.J., Stefanescu, D., Mahmoudi, A.H., Truman, C.E., Smith, D.J., Novel applications of the deep-hole drilling technique for measuring through-thickness residual stress distributions (2006) J ASTM Int, 3 (4), pp. 1-12; George, D., Kingston, E., Smith, D.J., Measurement of through-thickness stresses using small holes (2002) J Strain Anal, 37 (2), pp. 125-139; Mahmoudi, A.H., Hossain, S., Truman, C.E., Smith, D.J., Pavier, M.J., A new procedure to measure near yield residual stresses using the deep-hole drilling technique (2009) J Exp Mech, 49 (4), pp. 595-604; Fitzpatrick, M.E., Lodini, A., (2003) Analysis of residual stress by diffraction using Neutron and Synchrotron radiation, , Taylor & francis, London; Robinson, J.S., Hossain, S., Truman, C.E., Paradowska, A.M., Hughes, D.J., Wimpory, R.C., Fox, M.E., Residual stress in 7449 aluminium alloy forgings (2010) Mater Sci Eng A, 527, pp. 2603-2612; Hossain, S., (2005) Residual stresses under conditions of high triaxiality, , PhD Thesis, University of Bristol; Hossain, S., Goudar, D.M., Truman, C.E., Smith, D.J., Simulation and measurement of residual stresses in a type 316H stainless steel offset repair in a pipe girth weld (2011) Mater Sci Forum, 681, pp. 492-497; Pirling, T., Bruno, G., Withers, P.J., SALSA - a new instrument for strain imaging in engineering materials and components (2006) Mater Sci Eng A, 437 (1), pp. 139-144; Hughes, D.J., Bruno, G., Pirling, T., Withers, P.J., Scientific Review: First Impressions of SALSA: The New Engineering Instrument at ILL (2006) Neutron News, 17 (3), pp. 28-320; Garcia Granada, A.A., George, D., Smith, D.J., (1998) Assessment of distortions in the deep-hole technique for measuring residual stress. In: Proceedings of the 11th Conference on Experimental Mechanics, Oxford, pp 1301–1306

PY - 2017/10

Y1 - 2017/10

N2 - An accurate characterisation of residual stress plays an important role in the structural integrity assessment of an engineering component. Several techniques and tools are available for measuring and predicting residual stresses. For example, neutron diffraction (ND) and X-ray diffraction (XRD) are non-destructive techniques used for measuring through-thickness and surface residual stresses respectively, while the deep-hole drilling (DHD) and the incremental centre-hole drilling (ICHD) are semi-destructive techniques and measure through-thickness and sub-surface residual stress respectively. In most open literature, a more favoured method is traditionally used over others, with some degree of validation using finite element analysis (FEA) predictive tool. In this paper it will be shown that the different methods and tools available are not contradicting or more superior to the others, but rather, the use of more than one available technique complementary to each other can improve the quality and the confidence in the characterisation of the residual stress state in an engineering component. In particular, the accurate knowledge of the residual stress field for a safety critical component plays a vital role for subsequent structural integrity assessment. © 2017, The Author(s).

AB - An accurate characterisation of residual stress plays an important role in the structural integrity assessment of an engineering component. Several techniques and tools are available for measuring and predicting residual stresses. For example, neutron diffraction (ND) and X-ray diffraction (XRD) are non-destructive techniques used for measuring through-thickness and surface residual stresses respectively, while the deep-hole drilling (DHD) and the incremental centre-hole drilling (ICHD) are semi-destructive techniques and measure through-thickness and sub-surface residual stress respectively. In most open literature, a more favoured method is traditionally used over others, with some degree of validation using finite element analysis (FEA) predictive tool. In this paper it will be shown that the different methods and tools available are not contradicting or more superior to the others, but rather, the use of more than one available technique complementary to each other can improve the quality and the confidence in the characterisation of the residual stress state in an engineering component. In particular, the accurate knowledge of the residual stress field for a safety critical component plays a vital role for subsequent structural integrity assessment. © 2017, The Author(s).

KW - autogenous welding

KW - conventional and modified deep-hole drilling

KW - finite element simulation

KW - neutron diffraction

KW - quenching

KW - Residual stress

KW - Characterization

KW - Neutron diffraction

KW - Nondestructive examination

KW - Quenching

KW - Residual stresses

KW - Safety engineering

KW - Structural integrity

KW - X ray diffraction

KW - Deep hole drilling

KW - Destructive techniques

KW - Finite element simulations

KW - Incremental centre hole drillings

KW - Non-destructive technique

KW - Safety critical components

KW - Structural integrity assessment

KW - Surface residual stress

KW - Finite element method

U2 - 10.1007/s40799-017-0193-2

DO - 10.1007/s40799-017-0193-2

M3 - Article (Academic Journal)

SN - 0732-8818

VL - 41

SP - 483

EP - 503

JO - Experimental Techniques

JF - Experimental Techniques

IS - 5

ER -

Application of multiple analysis methods in optimising complex residual stress characterisation

Abstract

Bibliographical note

Keywords

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