Residual stress is that which remains in a body that is stationary and at equilibrium with its surroundings. It can be very detrimental to the performance of a material or the life of a component. Alternatively, beneficial residual stresses can be introduced deliberately. Residual stresses are more difficult to predict than the in-service stresses on which they superimpose. For this reason, it is important to have reliable methods for the measurement of these stresses and to understand the level of information they can provide. In this paper, which is the first part of a two part overview, the effect of residual stresses on fatigue lifetimes and structural integrity are first summarised, followed by the definition and measurement of residual stresses. Different types of stress are characterised according to the characteristic length scale over which they self-equilibrate. By comparing this length to the gauge volume of each technique, the capability of a range of techniques is assessed. In the sec...

Residual stress. Part 1 – Measurement techniques

http://doras.dcu.ie/17607/1/Review_of_residual_stresses-Final.pdf

Methods of measuring residual stresses in components

Our safety, comfort and peace of mind are heavily dependent upon our capability to prevent, predict or postpone the failure of components and structures on the basis of sound physical principles While the external loadings acting on a material or component are clearly important, There are other contributory factors including unfavourable materials microstructure, pre-existing defects and residual stresses Residual stresses can add to, or subtract from, the applied stresses and so when unexpected failure occurs it is often because residual stresses have combined critically with the applied stresses, or because together with the presence of undetected defects they have dangerously lowered the applied stress at which failure will occur Consequently it is important that the origins of residual stress are understood, opportunities for removing harmful or introducing beneficial residual stresses recognized, their evolution in-service predicted, their influence on failure processes understood and safe structural integrity assessments made, so as to either remove the part prior to failure, or to take corrective action to extend life This paper reviews the progress in these aspects in the light of the basic failure mechanisms

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Residual stress and its role in failure

A powerful new method for residual stress measurement is presented. A part is cut in two, and the contour, or profile, of the resulting new surface is measured to determine the displacements caused by release of the residual stresses. Analytically, for example using a finite element model, the opposite of the measured contour is applied to the surface as a displacement boundary condition. By Bueckner's superposition principle, this calculation gives the original residual stresses normal to the plane of the cut. This contour method is more powerful than other relaxation methods because it can determine an arbitrary cross-sectional area map of residual stress, yet more simple because the stresses can be determined directly from the data without a tedious inversion technique. The new method is verified with a numerical simulation, then experimentally validated on a steel beam with a known residual stress profile.

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Cross-sectional mapping of residual stresses by measuring the surface contour after a cut

Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice

Significant levels of residual stress are developed in the production of thick-section steel welds. Residual stress can be measured by a variety of methods, although few offer the ability to determine the spatial distribution completely through the thickness. This paper summarizes recent developments in the deep-hole method for measuring residual stresses in thick-section welds. Experimental results obtained from a variety of welded steel components are described. The measurement method has also been used to provide validation for finite element simulations of residual stresses in a welded cylinder-to-nozzle stainless steel component. The paper describes the finite element weld analysis and compares the results with measurements obtained from several locations in the complex geometry. Overall, there is good agreement between the predicted and measured distributions of residual stress, but the magnitudes of predicted stress tend to be greater.

Measurement and prediction of residual stresses in thick section steel welds

The development of a deep hole method, based on earlier techniques, for measuring the through-thickness distribution of residual stresses is described. The distortion of a reference hole used in the method was interpreted using analytical techniques to determine the residual stresses present. The accuracy of the method was investigated using a 100 mm deep plastically deformed ferritic steel rectangular bar. The stresses in the bar were determined by surface strain gauges. The axial residual stresses through the depth of the bar, measured by the deep hole method, were found to be within ± 35 MPa of the stresses determined from the strain gauges in the central 80 mm of the bar.

Development and experimental validation of the deep hole method for residual stress measurement

Mechanical strain relief techniques for estimating the magnitude of residual stress work by measuring strains or displacements when part of the component is machined away. The underlying assumption is that such strain or displacement changes result from elastic unloading. Unfortunately, in components containing high levels of residual stress, elastic-plastic unloading may well occur, particularly when the residual stresses are highly triaxial. This paper examines the performance of one mechanical strain relief technique particularly suitable for large section components, the deep hole drilling (DHD) technique. The magnitude of error is calculated for different magnitudes of residual stress and can be substantial for residual stress states close to yield. A modification to the technique is described to allow large magnitudes of residual stress to be measured correctly. The new technique is validated using the case of a quenched cylinder where use of the standard DHD technique leads to unacceptable error. The measured residual stresses using the new technique are compared with the results obtained using the neutron diffraction technique and are shown to be in excellent agreement.

A New Procedure to Measure Near Yield Residual Stresses Using the Deep Hole Drilling Technique

This paper presents novel applications of the deep-hole drilling technique for residual stress measurement in components The results outline the versatility of this technique for application in complex situations such as residual stress measurement in very thick components, components with difficult access to the measurement location, very large components, components requiring high spatial resolution, and components requiring detailed near surface residual stress distribution The deep-hole drilling measurements were compared with results obtained using other measurement techniques Excellent agreement was found between the results

Novel Applications of the Deep-Hole Drilling Technique for Measuring Through-Thickness Residual Stress Distributions

Previously the deep-hole method was developed to measure residual stresses in thick-section engineering components. In this paper it is demonstrated that stresses arising from external applied loading can also be measured. A series of calibration studies using aluminium and steel samples, with thicknesses varying from 5 to 50 mm, are presented. The samples were subjected to tensions, bending and torsion. It is shown that the deep-hole method can measure linear and non-linear stress distributions.

David Smith

Papers

Measurement and prediction of residual stresses in thick section steel welds

Development and experimental validation of the deep hole method for residual stress measurement

A New Procedure to Measure Near Yield Residual Stresses Using the Deep Hole Drilling Technique

Novel Applications of the Deep-Hole Drilling Technique for Measuring Through-Thickness Residual Stress Distributions

Measurement of through-thickness stresses using small holes