Towards good practice guidelines for the contour method of residual stress measurement

Hosseinzadeh, Foroogh; Kowal, Jan; Bouchard, P. J.

doi:10.1049/joe.2014.0134

Cited by 96 publications

(90 citation statements)

References 40 publications

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“…Alternatively, Kartal [6] has developed analytical solutions for samples with simple geometry, which have been used to analyse residual stresses developed during welding [7]. Further details of the contour method are described elsewhere [5,8,9].…”

Section: Introductionmentioning

confidence: 99%

“…Several sources of errors in the cutting step could lead to significant uncertainties in the measured results. These include cutting artefacts, bulge errors and plastic deformation [5,8,10]. The errors (e.g.…”

Section: Introductionmentioning

confidence: 99%

“…The errors (e.g. cutting artefacts), which are entirely associated with the nature of WEDM cutting and are independent of the stress state in the sample, can be avoided in most cases [8,10]. Also, they could be rectified in the data processing step, or they could be corrected for by performing a test cut [4,5].…”

Section: Introductionmentioning

confidence: 99%

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Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

et al. 2017

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Cutting-induced plasticity can lead to elevated uncertainties in residual stress measurements made by the contour method. In this study plasticity-induced stress errors are numerically evaluated for a benchmark edge-welded beam to understand the underlying mechanism. Welding and cutting are sequentially simulated by finite element models which have been validated by previous experimental results. It is found that a cutting direction normal to the symmetry plane of the residual stress distribution can lead to a substantially asymmetrical back-calculated stress distribution, owing to cutting-induced plasticity. In general, the stresses at sample edges are most susceptible to error, particularly when the sample is restrained during cutting. Inadequate clamping (far from the plane of cut) can lead to highly concentrated plastic deformation in local regions, and consequently the back-calculated stresses have exceptionally high values and gradients at these locations. Furthermore, the overall stress distribution is skewed towards the end-of-cut side. Adequate clamping (close to the plane of cut) minimises errors in back-calculated stress which becomes insensitive to the cutting direction. For minimal constraint (i.e. solely preventing rigid body motion), the plastic deformation is relatively smoothly distributed, and an optimal cutting direction (i.e. cutting from the base material towards the weld region in a direction that falls within the residual stress symmetry plane) is identified by evaluating the magnitude of stress errors. These findings suggest that cutting process information is important for the evaluation of potential plasticity-induced errors in contour method results, and that the cutting direction and clamping strategy can be optimised with an understanding of their effects on plasticity and hence the back-calculated stresses.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

et al. 2017

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“…The values that were applied for the modulus and for Poisson's ratio were 210 GPa and 0.27, respectively. This contour method analysis was carried out according to current best practice [7].…”

Section: Residual Stress Measurementsmentioning

confidence: 99%

An evaluation of multipass narrow gap laser welding as a candidate process for the manufacture of nuclear pressure vessels

Feng

Rathod

Roy

et al. 2017

International Journal of Pressure Vessels and Piping

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Nuclear pressure vessels are currently fabricated using arc welding processes.Recently, considerable effort has been directed at the development of electron beam welding as an alternative fabrication technique owing to the substantial productivity gains it would offer. However, little attention has been directed at laser-based techniques. In this work we evaluate the potential for applying multipass narrow-gap laser welding (NGLW) to the fabrication of nuclear pressure vessels, based on the characterization of a 30 mm thick weld in SA508 steel. Although still a multipass process, the number of passes is reduced in comparison to an arc weld of the same thickness, and the deposition of successive passes provides a degree of tempering to previously deposited weld metal in a way that the electron beam welding process does not. Principal engineering challenges 2 for the implementation of multipass NGLW include the achievement of appropriate joint fit-up, and the shielding of a molten pool at the base of a deep and narrow weld groove.

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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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Towards good practice guidelines for the contour method of residual stress measurement

Cited by 96 publications

References 40 publications

Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

An evaluation of multipass narrow gap laser welding as a candidate process for the manufacture of nuclear pressure vessels

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

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