Controlling the Cut in Contour Residual Stress Measurements of Electron Beam Welded Ti-6Al-4V Alloy Plates

Hosseinzadeh, Foroogh; Ledgard, Peter; Bouchard, P. J.

doi:10.1007/s11340-012-9686-1

Cited by 52 publications

(59 citation statements)

References 20 publications

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“…According to Refs. [20,21], the stresses at the cut tip during the cutting procedure cause the material to deform, and some bulge errors tend to cause stress profiles to show a reduced peak stress magnitude. In general, contour results are uncertain near the edges of the cut and should not be reported in that region unless special care is taken to get better results there [22].…”

Section: Comparison Of Simulated and Experimental Resultsmentioning

confidence: 99%

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

Xie

Zhao

et al. 2015

Acta Metall. Sin. (Engl. Lett.)

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This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates (50 mm thick) by using finite element and contour measurement methods. A three-dimensional finite element model of 50-mmthick titanium component was proposed, in which a column-cone combined heat source model was used to simulate the temperature field and a thermo-elastic-plastic model to analyze residual stress in a weld joint based on ABAQUS software. Considering the uncertainty of welding simulation, the computation was calibrated by experimental data of contour measurement method. Both test and simulated results show that residual stresses on the surface and inside the weld zone are significantly different and present a narrow and large gradient feature in the weld joint. The peak tensile stress exceeds the yield strength of base materials inside weld, which are distinctly different from residual stress of the thin Ti-6Al-4V alloy plates presented in references before.

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Section: Comparison Of Simulated and Experimental Resultsmentioning

confidence: 99%

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

Xie

Zhao

et al. 2015

Acta Metall. Sin. (Engl. Lett.)

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“…Commercial wire electro discharge machining (EDM) machines are optimised for conventional applications involving a rough cut followed by several finishing skim cuts to produce a suitable surface finish. However, for the contour method, EDM cutting conditions must be selected for a single cut that produces the surface finish with lowest roughness while minimising cutting artefacts [35]. For the welded plate considered here, the cutting parameters were chosen based on previous experience of cutting ferritic and austenitic materials of similar thickness.…”

Section: Residual Stress Measurement Using Contour Methodsmentioning

confidence: 99%

“…EDM wire entry and exit from the test specimen can introduce cutting artefacts that affect near-surface measurements [35]. Figure 1(a) shows the position of the cut in the welded plate, where the wire entry (A) refers to the end of the specimen that the cut starts where the running wire enters the test specimen and similarly wire exit (B) relates where the running wire leaves the test specimen.…”

Section: Residual Stress Measurement Using Contour Methodsmentioning

confidence: 99%

“…Figure 1(a) shows the position of the cut in the welded plate, where the wire entry (A) refers to the end of the specimen that the cut starts where the running wire enters the test specimen and similarly wire exit (B) relates where the running wire leaves the test specimen. To mitigate wire entry and exit cutting artefacts, sacrificial layers [35] were bonded to the outer surface of the plate to create a uniform cross-section and help avoid cutting artefacts. The plate was rigidly clamped in an Agie Charmilles wire EDM machine (CUT 1000) and the contour cut was performed.…”

Section: Residual Stress Measurement Using Contour Methodsmentioning

confidence: 99%

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Examining Stress Relaxation in a Dissimilar Metal Weld Subjected to Postweld Heat Treatment

Venkata¹,

Khayatzadeh²,

Achouri

et al. 2018

Materials Performance and Characterization

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Dissimilar metal welds are often required in nuclear power plants to join components made from austenitic steels to those from ferritic steels, particularly in fast breeder reactor plants to join the intermediate heat exchanger to the steam generator. The process of welding alters the microstructure of the base materials and also causes residual stresses to form, both due to the change in the microstructure and the differing thermal histories in various regions. Post-weld heat treatment (PWHT) is required to relieve the residual stresses and achieve preferable microstructural gradients across the weld joint. Therefore, in order to arrive at the optimal PWHT process, it is necessary to investigate the effects of heat treatment on the joint integrity, microstructure and residual stress relaxation in the welds.To investigate this effect of PWHT on the residual stress relaxation and corresponding alteration of microstructure across a welded joint, a dissimilar weld between modified 9Cr-1Mo (P91) steel and austenitic stainless steel AISI 316LN was made using autogenous electron beam (EB) welding. To achieve this, the welding process was first modelled numerically using finite element analysis and the residual stress predictions were validated with experimental investigation using neutron diffraction. The validated model was then used to study the residual stress relaxation through the simulation of PWHT. The predicted stress relaxation was compared with contour method measurement of residual stresses in the actual welded plate subjected to PWHT. The results indicate that albeit some relaxation of residual stresses during PWHT, there is still a significant portion of highly localised residual stresses left in the specimen.

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“…There are a number of potential types and location of wire EDM cutting errors and artefacts [8][9]: wire entry and exit artefacts; artefacts at the start of cut; wire breakage; and bowing and waviness of the cut surface. Errors can be symmetric and anti-symmetric with respect to the two cut surfaces.…”

Section: Introductionmentioning

confidence: 99%

Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

Ahmad

Fitzpatrick

2015

Metall Mater Trans A

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The contour method of residual stress measurement relies on the careful application of wire electro-discharge machining (WEDM) for the cutting stage. Changes in material removal rates during the cut lead to errors in the final calculated values of residual stress. In this study WEDM cutting parameters have been explored to identify the optimum conditions for contour method residual stress measurements. The influence of machine parameters on the surface roughness and cutting artefact of the contour cut are discussed. It has been identified that the critical parameter in improving the surface finish is the spark pulse duration. A typical cutting artefact and its impact on measured stress values has been identified and demonstrated for a contour cut in a welded marine steel. A procedure is presented to correct contour displacement data from the influence of WEDM cutting artefacts, and is demonstrated on the correction of a measured weld residual stress. The corrected contour method improved the residual stress magnitude up to 150 MPa. The corrected contour method results were validated by X-ray diffraction, incremental centre hole drilling and neutron diffraction.

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Controlling the Cut in Contour Residual Stress Measurements of Electron Beam Welded Ti-6Al-4V Alloy Plates

Cited by 52 publications

References 20 publications

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

Examining Stress Relaxation in a Dissimilar Metal Weld Subjected to Postweld Heat Treatment

Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

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