Comparison of Residual Stress Measurements Conducted by X-ray Stress Analysis and Incremental Hole Drilling Method
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Comparison of Residual Stress Measurements Conducted by Xray Stress Analysis and Incremental Hole Drilling Method K. Bobzin1 • W. Wietheger1 • M. A. Knoch1 • A. Schacht1 • U. Reisgen2 R. Sharma2 • L. Oster2
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Submitted: 14 November 2019 / in revised form: 20 May 2020 The Author(s) 2020
Abstract The level of residual stresses is of great importance for many applications. In this work, the two established residual stress analysis methods x-ray stress analysis and incremental hole-drilling combined with electronic speckle pattern interferometry are compared. Each stress analysis method has its specific limitations. Furthermore, the residual stress state of a material is influenced by its processing history. To compare both methods, aluminumbased specimens (AlCu6Mn, AlZn5.5MgCu) with different processing histories were investigated. Measurements with both methods were conducted on the same specimens and on the same measurement spots. Highest stress levels were found in the mechanically machined specimen, while heat treatment via tempering or deposition welding shows reduced stress levels inside of the specimens. In case of cold spraying, the stresses in the feedstock material are considered negligible. In contrast, cold-spray coatings deposited on construction steel substrate exhibited tensile stresses, which relax over time at room temperature.
This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & A. Schacht [email protected] 1
Surface Engineering Institute (IOT), RWTH Aachen University, Aachen, Germany
2
Welding and Joining Institute (ISF), RWTH Aachen University, Aachen, Germany
Keywords aluminum alloys \ feedstock cold spray \ processing hole drilling method \ testing residual stress determination \ testing x-ray diffraction (XRD) \ testing
Introduction Coating, welding and additive manufacturing are key manufacturing processes in modern production lines and can be found across a wide field of technical applications. Especially the processing of metallic components is often followed by an inhomogeneous thermal heat input leading to the formation of residual stresses. The distribution and magnitude of the residual stresses play an important role for the correct design of the product and its manufacturing processes as residual stresses can have either a positive or a negative effect on the load-bearing capabilities (Ref 1). The formation of residual stresses during coating processes may result in cracks or even the delamination of the coating (Ref 2). Welding is mainly characterized by thermal distortion. Residual stresses can have a negative impact on the alternating load resistance. Similarly, additive manufacturing p
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