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Article
Publication date: 4 July 2016

Davood Afshari, M. Sedighi, M.R. Karimi and Z. Barsoum

The purpose of this paper is to predict residual stresses in resistance spot weld of 2 mm thick aluminum 6061-T6 sheets. The joint use of finite element analysis and artificial…

Abstract

Purpose

The purpose of this paper is to predict residual stresses in resistance spot weld of 2 mm thick aluminum 6061-T6 sheets. The joint use of finite element analysis and artificial neural networks can eliminate the high costs of residual stresses measuring tests and significantly shorten the time it takes to arrive at a solution.

Design/methodology/approach

Finite element method and artificial neural network have been used to predict the residual stresses. Different spot welding parameters such as the welding current, the welding time and the electrode force have been used for the simulation purposes in a thermal-electrical-structural coupled finite element model. To validate the numerical results, a series of experiments have been performed, and residual stresses have been measured. The results obtained from the finite element analysis have been used to build up a back-propagation artificial neural network model for residual stresses prediction.

Findings

The results revealed that the neural network model created in this study can accurately predict residual stresses produced in resistance spot weld. Using a combination of these two developed models, the residual stresses can be predicted in terms of spot weld parameters with high speed and accuracy.

Practical implications

The paper includes implication for aircraft and automobile industries to predict residual stresses. Residual stresses can lower the strength and fatigue life of the spot-welded joints and determine the performance quality of the structure.

Originality/value

This paper presents an approach to reduce the high costs and long times of residual stresses measuring tests.

Details

Aircraft Engineering and Aerospace Technology: An International Journal, vol. 88 no. 4
Type: Research Article
ISSN: 1748-8842

Keywords

Article
Publication date: 8 March 2011

Yuji Sano, Koichi Akita, Kazuya Takeda, Rie Sumiya, Toshiyuki Tazawa, Toshiyuki Saito and Chihiro Narazaki

The purpose of this paper is to investigate the behavior of compressive residual stress induced by laser peening under external loading on an age‐hardened high‐strength aluminum…

Abstract

Purpose

The purpose of this paper is to investigate the behavior of compressive residual stress induced by laser peening under external loading on an age‐hardened high‐strength aluminum alloy A2024‐T3, a low‐carbon austenitic stainless steel SUS316L (Type 316L) and a nickel‐based alloy NCF600 (Alloy 600).

Design/methodology/approach

The surface residual stress was measured intermittently by X‐ray diffraction during cyclic uniaxial loading.

Findings

The compressive residual stress due to laser peening significantly decreased during the first few cycles at stress ratio of 0.1 with the maximum loading stress exceeding the 0.2 per cent yield stress. No remarkable decrease was observed afterward until the end of the loading cycles.

Originality/value

Under symmetric loading at the stress ratio of −1 to A2024‐T3, a major decrease took place in the compression side of the first loading cycle. The surface residual stresses remained in compression within all the extent of the present experiments, even if the maximum loading stress exceeded the yield stress of the materials.

Details

International Journal of Structural Integrity, vol. 2 no. 1
Type: Research Article
ISSN: 1757-9864

Keywords

Article
Publication date: 8 March 2011

Kelly S. Carney, Omar Hatamleh, James Smith, Thomas Matrka, Amos Gilat, Michael Hill and Chanh Truong

The purpose of this paper is to present an analytical framework for predicting the residual stresses that result from the laser shock peening of a friction stir‐welded 2195…

Abstract

Purpose

The purpose of this paper is to present an analytical framework for predicting the residual stresses that result from the laser shock peening of a friction stir‐welded 2195 aluminum alloy sample, using the finite element software LS‐DYNA.

Design/methodology/approach

The pressures resulting from the laser peening are directly applied in an explicit transient analysis as forces. At the completion of the transient analysis, an implicit springback analysis is performed to determine the final residual stresses. This cycle is repeated for the appropriate number of peen applications, including the appropriate overlap of application areas. To validate the analytical framework, a comparison of residual stresses between analysis and a test specimen is made using laser‐peened base material which was not friction stir‐welded. Friction stir welding (FSW) causes residual stresses and material property variations. In this work, the varying material properties regions are simplified and defined as discrete, separate materials. The residual stresses resulting from the welding are introduced directly as initial conditions in the peening transient analysis and so are combined within the analysis with the residual stresses from the peening.

Findings

Comparisons made between the experimental and analytical residual stresses are generally favorable.

Originality/value

Analysis of the laser shock peening of FSW has not been accomplished previously.

Details

International Journal of Structural Integrity, vol. 2 no. 1
Type: Research Article
ISSN: 1757-9864

Keywords

Article
Publication date: 6 September 2019

Mostafa Yakout, M.A. Elbestawi, S.C. Veldhuis and S. Nangle-Smith

Residual stresses are induced during selective laser melting (SLM) because of rapid melting, solidification and build plate removal. This paper aims to examine the thermal cycle…

1094

Abstract

Purpose

Residual stresses are induced during selective laser melting (SLM) because of rapid melting, solidification and build plate removal. This paper aims to examine the thermal cycle, residual stresses and part distortions for selected aerospace materials (i.e. Ti-6Al-4V, stainless steel 316L and Invar 36) using a thermo-mechanical finite element model. The numerical results are validated and compared to experimental data.

Design/methodology/approach

The model predicts the residual stress and part distortion after build plate removal. The residual stress field is validated using X-ray diffraction method and the part distortion is validated using dimensional measurements.

Findings

The trends found in the numerical results agree with those found experimentally. Invar 36 had the lowest tensile residual stresses because of its lowest coefficient of thermal expansion. The residual stresses of stainless steel 316L were lower than those of Ti-6Al-4V because of its high thermal diffusivity.

Research limitations/implications

The model predicts residual stresses at the optimal SLM process parameters. However, using any other process conditions could cause void formation and/or alloying element vaporization, which would require the inclusion of melt pool physics in the model.

Originality/value

The paper explains the influence of the coefficient of thermal expansion and thermal diffusivity on the induced thermal stresses using experimental and numerical results. The methodology can be used to predict the part distortions and residual stresses in complex designs of any of the three materials under optimal SLM process parameters.

Details

Rapid Prototyping Journal, vol. 26 no. 1
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 1 August 1999

Jaroslav Mackerle

This paper gives a bibliographical review of the finite element methods (FEMs) applied to the analysis of ceramics and glass materials. The bibliography at the end of the paper…

2603

Abstract

This paper gives a bibliographical review of the finite element methods (FEMs) applied to the analysis of ceramics and glass materials. The bibliography at the end of the paper contains references to papers, conference proceedings and theses/dissertations on the subject that were published between 1977‐1998. The following topics are included: ceramics – material and mechanical properties in general, ceramic coatings and joining problems, ceramic composites, ferrites, piezoceramics, ceramic tools and machining, material processing simulations, fracture mechanics and damage, applications of ceramic/composites in engineering; glass – material and mechanical properties in general, glass fiber composites, material processing simulations, fracture mechanics and damage, and applications of glasses in engineering.

Details

Engineering Computations, vol. 16 no. 5
Type: Research Article
ISSN: 0264-4401

Keywords

Article
Publication date: 1 October 2006

Peter Mercelis and Jean‐Pierre Kruth

This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this…

26447

Abstract

Purpose

This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon.

Design/methodology/approach

First, the origin of residual stresses is explored and a simple theoretical model is developed to predict residual stress distributions. Next, experimental methods are used to measure the residual stress profiles in a set of test samples produced with different process parameters.

Findings

Residual stresses are found to be very large in SLM parts. In general, the residual stress profile consists of two zones of large tensile stresses at the top and bottom of the part, and a large zone of intermediate compressive stress in between. The most important parameters determining the magnitude and shape of the residual stress profiles are the material properties, the sample and substrate height, the laser scanning strategy and the heating conditions.

Research limitations/implications

All experiments were conducted on parts produced from stainless steel powder (316L) and quantitative results cannot be simply extrapolated to other materials. However, most qualitative results can still be generalized.

Originality/value

This paper can serve as an aid in understanding the importance of residual stresses in SLS/SLM and other additive manufacturing processes involving a localized heat input. Some of the conclusions can be used to avoid problems associated with residual stresses.

Details

Rapid Prototyping Journal, vol. 12 no. 5
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 1 January 2009

X.Q. Zhang

widely‐used hypoelastic model for four well‐known objective stress rates under a four‐phase stress cycle associated with axial tension and/or torsion of thin‐walled cylindrical…

Abstract

widely‐used hypoelastic model for four well‐known objective stress rates under a four‐phase stress cycle associated with axial tension and/or torsion of thin‐walled cylindrical tubes. Here, two kinds of models based upon the Cauchy stress and the Kirchhoff stress will be treated. The reduced systems of differential equations of these rate constitutive equations are derived and studied for Jaumann, Green‐ Naghdi, logarithmic and Truesdell stress rates, separately. Analytical solutions in some cases and numerical solutions in all cases are obtained using these reduced systems. Comparisons between the residual deformations are made for different cases. It may be seen that only the logarithmic stress rate results in no residual deformation. In particular, results indicate that Green‐Naghdi rate would generate unexpected residual deformation effect that is essentially different from that resulting from Jaumann rate. On the other hand, it is realized that this study accomplishes an alternative, direct proof for the nonintegrability problem of Truesdell’s hypoelastic rate equation with classical stress rates. This problem has been first treated successfully by Simo and Pister in 1984 using Bernstein’s integrability conditions. However, such treatment needs to cope with a coupled system of nonlinear partial differential equations in Cauchy stress. Here, a different idea is used. It is noted that every integrable hypoelastic equation is just an equivalent rate form of an elastic equation and hence should produce no residual deformations under every possible stress cycle. Accordingly, a hypoelastic model with a stress rate has to be non‐integrable, whenever a stress cycle can be found under which this model generates residual deformation. According to this idea of reductio ad absurdum, a well‐designed stress cycle is introduced and the corresponding residual deformations are calculated. Unlike the treatment of Bernstein’s integrability conditions, it may be a simple and straightforward matter to calculate the final deformations for a given stress cycle. This has been done in this study for several well‐known stress rates.

Details

Multidiscipline Modeling in Materials and Structures, vol. 5 no. 1
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 26 May 2022

Mohammad Qasim Shaikh, Thomas A. Berfield and Sundar V. Atre

The purpose of this paper is to investigate a simulation solution for estimating the residual stresses developed in metal fused filament fabrication (MF3) printed parts…

Abstract

Purpose

The purpose of this paper is to investigate a simulation solution for estimating the residual stresses developed in metal fused filament fabrication (MF3) printed parts. Additionally, to verify these estimates, a coupled experimental–computational approach using the crack-compliance method was investigated in this study.

Design/methodology/approach

In this study, a previously validated thermomechanical process simulation was used to estimate the residual stresses developed in the MF3 printing process. Metal-filled polymer filament with a solids loading of 59 Vol.% Ti-6Al-4V was studied. For experimental validation of simulation predictions, the MF3 printed green parts were slitted incrementally and the corresponding strains were measured locally using strain gauges. The developed strain was modeled in finite-element-based structural simulations to estimate a compliance matrix that was combined with strain gauge measurements to calculate the residual stresses. Finally, the simulation results were compared with the experimental findings.

Findings

The simulation predictions were corroborated by the experimental results. Both results showed the same distribution pattern, that is, tensile stresses at the outer zone and compressive stresses in the interior. In the experiments, the residual stresses varied between 1.02 MPa (tension) and −2.28 MPa (compression), whereas the simulations were predicted between 1.37 MPa (tension) and −1.39 MPa (compression). Overall, there was a good quantitative agreement between the process simulation predictions and the experimental measurements, although there were some discrepancies. It was concluded that the thermomechanical process simulation was able to predict the residual stresses developed in MF3 printed parts. This validation enables the printing process simulation to be used for optimizing the part design and printing parameters to minimize the residual stresses.

Originality/value

The applicability of thermomechanical process simulation to predict residual stresses in MF3 printing is demonstrated. Additionally, a coupled experimental–computational approach using the crack-compliance method was used to experimentally determine residual stresses in the three-dimensional printed part to validate the simulation predictions. Moreover, this paper presents a methodology that can be used to predict and measure residual stresses in other additive manufacturing processes, in general, though MF3 was used as demonstrator in this work.

Article
Publication date: 30 April 2020

Gang Wang, Yue Zhang, Chen Gao, GuangTao Xu and MingHao Zhao

The purpose of this paper is to investigate, the effects of residual stress and microstructure on the corrosion behaviour of carburised 18CrNiMo7-6 steel in a 3.5% NaCl aqueous…

Abstract

Purpose

The purpose of this paper is to investigate, the effects of residual stress and microstructure on the corrosion behaviour of carburised 18CrNiMo7-6 steel in a 3.5% NaCl aqueous solution.

Design/methodology/approach

The electrochemical tests were conducted using an electrochemical workstation with a three-electrode system in a 3.5% NaCl aqueous solution, the residual stress of each working face was measured by a high-speed residual stress analyser, and microstructure of different carburised layers were observed scanning electron microscopy. Finally, the effect of carbon content, microstructure and residual stress on the corrosion behaviour of the steel was discussed.

Findings

The results showed that the residual compressive stress in the carburised layer initially increased and subsequently decreased with increasing depth of the carburised layer, reaching stability in the matrix layer. The electrochemical tests before and after stress reduction showed that the electrochemical impedance and the electrochemical potential increased with the reduction of residual compressive stress.

Originality/value

The residual compressive stress in the carburised layer initially increases and subsequently decreases with increasing carburised layer depth. The electrochemical impedance and the electrochemical potential increased with the reduction of residual compressive stress. The general relationship between electrochemical potential and residual stress was established.

Details

Anti-Corrosion Methods and Materials, vol. 67 no. 4
Type: Research Article
ISSN: 0003-5599

Keywords

Article
Publication date: 3 March 2022

Changpeng Chen, Zhongxu Xiao, Gang Xue, Hailong Liao and Haihong Zhu

High temperature gradient induces high residual stress, producing an important effect on the part manufacturing during laser powder bed fusion (LPBF). The purpose of this study is…

Abstract

Purpose

High temperature gradient induces high residual stress, producing an important effect on the part manufacturing during laser powder bed fusion (LPBF). The purpose of this study is to investigate the effect of the molten pool mode on the thermal stress of Ti-6Al-4V alloy during different deposition processes.

Design/methodology/approach

A coupled thermal-mechanical finite element model was built. The developed model was validated by comparing the numerical results with the experimental data in the maximum molten pool temperature, the molten pool dimension and the residual stress described in the previous work.

Findings

For the single-track process, the keyhole mode caused an increase in both the maximum stress and the high-stress area compared with the conduction mode. For the multitrack process, a lower tensile stress around the scanning track and a higher compressive stress below the scanning track were found in the keyhole mode. For the multilayer process, the stress along the scanning direction at the middle of the part changed from tensile stress to compressive stress with the increase in the deposition layer number. As the powder layer number increased, the stress along the scanning direction near the top surface of the part decreased while the stress along the deposition direction obviously increased, indicating that the stress along the deposition direction became the dominant stress. The keyhole mode can reduce the residual stress near the top of the part, and the conduction mode was more likely to produce a low residual stress near the bottom of the part.

Originality/value

The results provide a systematic understanding of thermal stress during the LPBF process.

Details

Rapid Prototyping Journal, vol. 28 no. 7
Type: Research Article
ISSN: 1355-2546

Keywords

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