An iterative technique for the reconstruction of residual stress fields in a butt-welded plate from experimental measurement, and comparison with welding process simulation

Chukkan, Jazeel Rahman; Wu, Guiyi; Fitzpatrick, Michael E.; Jones, Steve; Kelleher, Joe

doi:10.1016/j.ijmecsci.2019.07.001

Cited by 20 publications

(5 citation statements)

References 19 publications

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“…[ 196 ] Moreover, there are several limitations as well as simplifications in FE models. [ 197 ] In this case, further studies combining ANN, experimental, and FE analyses are suggested for future investigations in the field of residual welding stresses.…”

Section: Origins and Effectsmentioning

confidence: 99%

Residual Stress in Engineering Materials: A Review

et al. 2021

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The accurate determination of residual stresses has a crucial role in understanding the complex interactions between microstructure, mechanical state, mode(s) of failure, and structural integrity. Moreover, the residual stress management concept contributes to industrial applications, aiming to improve the product's service performance and life cycle. In this regard, the industry requests rapid, efficient, and modern methods to identify and control the residual stress state. This review article contains three main sections. The first section covers different residual stress determination methods and reports the advancements over the recent decade. The second section includes the role of residual stresses in the performance of a broad range of materials including metallic alloys, polymers, ceramics, composites, and biomaterials. This is presented by classifying different science areas dealing with residual stresses into two main groups, including “origins” and “effects” of residual stresses. The range of topics covered are “welding, machining, curing/cooling, and spray coating processes,” “medical and dental sciences,” and “fatigue and fracture mechanisms.” The third section summarizes various strategies to effectively control residual stresses through different manufacturing procedures. It is hoped that the data provided herein serves as a valuable up‐to‐date reference for engineers and scientists in the field of residual stress.

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Section: Origins and Effectsmentioning

confidence: 99%

Residual Stress in Engineering Materials: A Review

et al. 2021

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“…Chukkan et al [48] developed a methodology to verify the state of residual stress in a butt-welded plate by using neutron diffraction for measurements. The measured residual stress was used to estimate the stress distribution, which was mapped by FEM on a weld plate.…”

Section: Position Experimental Large Distortion Theory Small Distortimentioning

confidence: 99%

Comparison of Finite Element Methods in Fusion Welding Processes—A Review

Marques

Silva

Péreira

2020

Metals

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Currently, welding processes have become one of the most used methods for joining materials in all kinds of industries, thanks to properties such as high speed and high tensile strength. However, despite these advantages, this type of connection method has some drawbacks, for example, residual stress and structural distortion, mainly due to the process thermal cycles. Structural distortion is one of the major concerns of industrial joining practice. In order to decrease distortion, the variation of welding sequence, direction, and clamping conditions, have been applied through several years, by trial and error tests. However, numerical simulation enables virtual examination of the welding, mainly due to the progress on the numerical methods, which stimulated the research on welding simulation models. These models can cover a wide spectrum of physical and thermal processes occurring during, and after welding. The aim of this paper is to provide wider information about types of finite element method (FEM) in fusion welding processes and to demonstrate the accuracy of FEM models results compared to experimental.

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“…The ease of access to high-performance workstations after the 2000s allowed the application of the inverse problem of eigenstrain to the solution of complex solid mechanics problems such as continuously processed bodies, [15] welds, [14,[17][18][19] and shot peened materials. [20][21][22][23][24] Full-field distribution of residual stresses was predicted by solving the inverse problem of eigenstrain [25][26][27] and hybrid reconstruction methods were also developed [28][29][30] for this purpose. Although these studies provide a very good match of linear elastic numerical model calculations with experimental data, which can be in the form of displacements or residual stresses, the reliability of eigenstrain evaluation is not clear.…”

Section: Introductionmentioning

confidence: 99%

Voxel‐Based Full‐Field Eigenstrain Reconstruction of Residual Stresses

Uzun

Korsunsky

2023

Adv Eng Mater

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Inverse eigenstrain (inherent strain) analysis methods are shown to be effective for the reconstruction of residual stresses in plane eigenstrain problems (continuously processed bodies) while conversely residual stress reconstruction in discontinuously processed bodies is extremely challenging and necessitates the use of complex regularizing assumptions. Herein, a new generic inverse eigenstrain method suitable for the reconstruction of residual stresses along with residual elastic strains and displacements in discontinuously processed bodies is introduced. The proposed method uses the superposition of eigenstrain radial basis functions together with a set of limited experimental data for model‐free (unconstrained) determination of unknown eigenstrain fields. This approach eliminates the limitations introduced by global basis functions such as polynomials. The novel point of this method is the ability to account for all six components of strain in an isotropic body without using regularizing assumptions. By lifting complex guiding formulation, the fidelity of full‐field eigenstrain reconstruction becomes directly related to the quality of experimental data and proper discretisation of the model domain. The FEniCS implementation has been validated using the experimental data of pointwise high‐energy synchrotron X‐ray diffraction measurements from a bent titanium alloy bar. A hybrid high throughput computing approach is also introduced for effective parallel computing.

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An iterative technique for the reconstruction of residual stress fields in a butt-welded plate from experimental measurement, and comparison with welding process simulation

Cited by 20 publications

References 19 publications

Residual Stress in Engineering Materials: A Review

Residual Stress in Engineering Materials: A Review

Comparison of Finite Element Methods in Fusion Welding Processes—A Review

Voxel‐Based Full‐Field Eigenstrain Reconstruction of Residual Stresses

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