Experimental and Numerical Simulation to Study the Reduction of Welding Residual Stress by Ultrasonic Impact Treatment

Chen, Jianfei; Chu, Jingyu; Jiang, Wenchun; Ye, Bin; Zhou, Fan; Wang, Zhenbo; Zhao, Peng

doi:10.3390/ma13040837

Cited by 24 publications

(9 citation statements)

References 33 publications

(54 reference statements)

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“…Moreover, comparing Figure 6 b,e, it was clear that the stress at the welded joint was effectively eliminated after the aging treatment (the original stress of the AW joint was actually the residual tensile stress, which was not conducive to its service life). It can be seen from Figure 6 c,f) that certain stress was introduced into the fine grain and plastic deformation zones of the welded joint after DSUIT (the stress introduced here was residual compressive stress, which was beneficial to the service life of the welded component [ 27 ]). The fine grain zone displayed red (high) stress (i.e., residual compressive stress), and the residual compressive stress near the welded joint surface was too large, which led to the missing phenomenon in the EBSD analysis process.…”

Section: Resultsmentioning

confidence: 99%

Improving the Properties of Laser-Welded Al–Zn–Mg–Cu Alloy Joints by Aging and Double-Sided Ultrasonic Impact Compound Treatment

Chen¹,

Liu²

2021

Materials

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To improve the loose structure and serious porosity of (Al–Zn–Mg–Cu) 7075 aluminum alloy laser-welded joints, aging treatment, double-sided ultrasonic impact treatment (DSUIT), and a combination of aging and DSUIT (A–DSUIT) were used to treat joints. In this experiment, the mechanism of A–DSUIT on the microstructure and properties of welded joints was analyzed. The microstructure of the welded joints was observed using optical microscopy, scanning electron microscopy, and electron backscatter diffraction (EBSD). The hardness and tensile properties of the welded components under the different processes were examined via Vickers hardness test and a universal tensile testing machine. The results showed that, after the aging treatment, the dendritic structure of the welded joints transformed into an equiaxed crystal structure. Moreover, the residual tensile stress generated in the welding process was weakened, and the hardness and tensile strength were significantly improved. After DSUIT, a plastic deformation layer of a certain thickness was generated from the surface downward, and the residual compressive stress was introduced to a certain depth of the joint. However, the weld zone unaffected by DSUIT still exhibited residual tensile stress. The inner microhardness of the joint surface improved; the impact surface hardness was the largest and gradually decreased inward to the weld zone base metal hardness, with a small improvement in the tensile strength. Compared with the single treatment process, the microstructural and mechanical properties of the welded joint after A–DSUIT were comprehensively improved. The microhardness and tensile strength of the welded joint reached 200 HV and 615 MPa, respectively, for an increase of 45.8% and 61.8%, respectively. Observation of the fractures of the tensile specimens under the different treatment processes showed that the fractures before the aging treatment were mainly ductile fractures while those after were mainly brittle fractures. After DSUIT of the welded joints, a clear and dense plastic deformation layer was observed in the fracture of the tensile specimens and effectively improved the tensile properties of the welded joints. Under the EBSD characterization, the larger the residual compressive stress near the ultrasonic impact surface, the smaller the grain diameter and misorientation angle, and the lower the texture strength. Finally, after A–DSUIT, the hardness and tensile properties improved the most.

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Section: Resultsmentioning

confidence: 99%

Improving the Properties of Laser-Welded Al–Zn–Mg–Cu Alloy Joints by Aging and Double-Sided Ultrasonic Impact Compound Treatment

Chen¹,

Liu²

2021

Materials

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“…6 Cheng et al 7 measured the residual stresses induced by the UIT process using experimental measurement techniques and found that a compressive stress layer is generated. Chen et al 8 investigated the effects of UIT on the residual stress in a repair welding joint by experimental and finite element (FE) methods. The longitudinal residual stresses basically were reduced to small tensile stresses from large tensile stresses, and the transverse residual stresses mainly decreased to compressive stresses from large tensile stresses after UIT.…”

Section: Introductionmentioning

confidence: 99%

High accuracy and efficiency calculation model for predicting the reduction of residual stress on large pressure vessels by ultrasonic impact surface treatment

Luo

Jiang

Zeng

2023

Engineering Reports

Self Cite

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Ultrasonic impact treatment (UIT) is a new surface strengthening method to reduce the residual stresses on large pressure vessels induced by surface and repair welding. An accurate and high efficiency calculation model is the key to accurately predicting the full‐field residual stresses on large pressure vessels under the UIT process. In this article, a full‐coverage impacting model is proposed to simulate the impacting process of the UIT pin. The effects of UIT on the residual stresses on repair and surface welded pressure vessels were investigated by explicit dynamic simulation. Experiments were also performed to verify the prediction results. Results show that the proposed full coverage impacting model can greatly improve the simulation precision and the calculation efficiency. The predicted residual stresses after the UIT process using the proposed model are consistent with the measured results. A remarkable reduction in residual stress was achieved in the zone subjected to UIT. The tensile residual stresses on the surface of the treated area were reduced to compressive stresses. With the increase of the impact velocity and the coverage rate, the residual stresses on the surface and transition layers decreased and then tended to stabilize. The impact coverage rate should not exceed 200% to avoid damage and save time.

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“…Therefore, many scholars have studied the reduction in residual stresses in various types of mechanical components. The commonly used methods to eliminate residual stresses include stress relief heat treatment [25], vibration time effect method [26,27], ultrasonic impact method [28], pulse magnetization method [29,30], etc. However, these methods have limitations while removing stress, such as high energy consumption, a long cycle of stress relief heat treatment, it difficulty in controlling the deformation of components after stress relief.…”

Section: Introductionmentioning

confidence: 99%

The Residual Stress and Deformation Control of TC4 Thin-Walled Outer Ring Components by Ultrasonic Regulation

Song

Pan

et al. 2022

Machines

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The deformation problem caused by the excessive residual stress has brought great challenges to the high-precision machining and geometrical stability of thin-walled components. Aiming to ensure the verticality within 0.012 mm after the processing and forming of a certain type of outer ring components, this paper firstly employs the ultrasonic critical refraction longitudinal wave (LCR wave) detection method to test the residual stress distribution in the key process. Additionally, the stress elimination effect of cryogenic stress relief treatment and the effect of residual stress on vertical deformation are analyzed. After that, combined with the self-developed ultrasonic stress relief (USR) equipment, the ultrasonic regulation treatment was used to replace the heat treatment stress relief process for the processing. The results show that after wire cutting and milling, excessive residual stress induces deformation of components, and USR method can eliminate machining residual stress more efficiently and quickly. As the whole component has torsional deformation along the cross section, the hole position at the upper and lower end faces is changed, which leads to the change in verticality. Finally, based on the results of X-ray diffraction (XRD), the potential microscopic mechanism of stress relief by ultrasonic treatment is analyzed. This study provides guidance for ultrasonic residual stress regulation to achieve the high-precision outer ring thin-walled components.

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Experimental and Numerical Simulation to Study the Reduction of Welding Residual Stress by Ultrasonic Impact Treatment

Cited by 24 publications

References 33 publications

Improving the Properties of Laser-Welded Al–Zn–Mg–Cu Alloy Joints by Aging and Double-Sided Ultrasonic Impact Compound Treatment

Improving the Properties of Laser-Welded Al–Zn–Mg–Cu Alloy Joints by Aging and Double-Sided Ultrasonic Impact Compound Treatment

High accuracy and efficiency calculation model for predicting the reduction of residual stress on large pressure vessels by ultrasonic impact surface treatment

The Residual Stress and Deformation Control of TC4 Thin-Walled Outer Ring Components by Ultrasonic Regulation

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