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Residual Stress and Fatigue of Metals

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Structural Integrity of Metals".

Deadline for manuscript submissions: closed (30 April 2023) | Viewed by 12809

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Special Issue Editors

Dr. Yun Luo

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Guest Editor

College of New Energy, China University of Petroleum (East China), Qingdao 266580, China
Interests: welding residual stress; fatigue; creep; life prediction
Special Issues, Collections and Topics in MDPI journals

Dr. Pengcheng Zhao

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Guest Editor

Key Laboratory of Pressure Systems and Safety, Ministry of Education, School of Mechanical and Power Engineering, East China University of Science and Technology, Shanghai 200237, China
Interests: fatigue; life prediction; microstructure characterization; deformation mechanism
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Dr. Huai Wang

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Guest Editor

School of Mechanical & Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
Interests: residual stress; metal plasticity; multiscale modelling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Nowadays, metal is one of the fundamental pillars of social progress, as well as the material basis of national economic development. Many mechanical components and structures are made of metal materials. During the fabrication of this metal components, the residual stresses are inevitably generated, which has a great influence on the structural integrity and service performance of the products. Whether it is traditional welding/joining/forming technology or newly developed additive manufacturing technology, the residual stress has always been a key factor affecting the reliability of mechanical structures. Fatigue is the main failure mode of the mechanical components and structures. Many failure experiences show that the location of fatigue failure is closely related to the distribution and magnitude of residual stress. Generally, the tensile residual stress promotes fatigue and fracture failure, while the compressive residual stress inhibits crack initiation and prolongs life. Therefore, the investigation on the residual stress, fatigue and the relationship between them is of great significance to ensure the long life and safe operation of metal structures.

The goal of the present Special Issue is to examine the recent contributions in the field of residual stress and fatigue of metals. The topics of interest include but are not limited to: experimental, theoretical and simulation analysis of the residual stresses, residual stresses reduction, fatigue life prediction, damage analysis, and fatigue life improvement by any engineering technologies, including design, process control and surface treatment, etc.

The authors are invited to publish their research results on all these topics, and therefore, we believe that this Special Issue will sufficiently demonstrate the recent advances in residual stress and fatigue of metals.

Dr. Yun Luo
Dr. Pengcheng Zhao
Dr. Huai Wang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

residual stress
fatigue
life assessment
welding and brazing
forming
simulation
measurement
controlling

Published Papers (7 papers)

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Research

17 pages, 5791 KiB

Open AccessArticle

A Uniformed Calculation Criterion on Heat Band Width of Local PWHT on Welded Joint with Dissimilar Thickness

by Yixuan Zhang, Jiameng Xie and Yun Luo

Metals 2023, 13(6), 1100; https://doi.org/10.3390/met13061100 - 10 Jun 2023

Viewed by 1639

Abstract

Local post-weld heat treatment is used to reduce welding residual stresses. The existing standards have great differences in the selection of the width of the heated band, and the heating width, as an important control parameter of the local heat treatment, will directly affect the quality of the heat treatment. In this paper, the numerical simulation method is used to simulate the welding and heat treatment process of unequal-thickness joints. The stress and deformation of the joint with different thickness ratios under different heating widths are studied by finite element simulation, focusing on the influence of the width of the heated band on the residual stress relief of the joint. Based on these studies, the criteria for determining the optimal width of the heating zone are consistent. Finally, the formula

H B = {H B}_{1} + {H B}_{2} = 3 \sqrt{R T} + \frac{1 + k}{2} \sqrt{R T}

for calculating local heat treatment heating width based on the thickness of welded joint for SA738Gr.B steel is established. Among them,

{H B}_{1}

is the width of the main heating zone,

{H B}_{2}

is the width of the auxiliary heating zone, k is the thickness ratio of the thick plate to the thin plate, and t is the wall thickness of the thin plate. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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13 pages, 4704 KiB

Open AccessFeature PaperArticle

Local Strengthening Design and Compressive Behavior Study of the Triangular Honeycomb Structure

by Qian Zhang, Wenwang Wu and Jianlin Liu

Metals 2022, 12(11), 1779; https://doi.org/10.3390/met12111779 - 22 Oct 2022

Cited by 6 | Viewed by 1747

Abstract

Additive manufacturing (AM) enables diversity in honeycomb structure configuration, which benefits optimization of the honeycomb structure. In the present study, we proposed two locally enhanced triangular honeycomb structures to improve in-plane compressive performance by avoiding diagonal fracture band. The compressive behaviors and failure mechanism of the original and enhanced triangular honeycomb structures made of 316L steel were studied by experiments and numerical simulations. The results show that the cell-enhanced triangular honeycomb structure and wall-enhanced triangular honeycomb structure possess significantly improved stiffness and peak load compared with the original structure. The fracture band along the diagonal direction of the triangular honeycomb structure is caused by buckling of the cell wall, which is related to its topologic structure. Stress distribution is an essential index reflecting the performance of a honeycomb structure. Uniform stress distribution makes the honeycomb structure fail layer by layer, and it can improve the peak load of the honeycomb structure. Defects such as unmelted metal particles and voids caused by AM processing weaken the strength and plasticity, and the resulting brittleness makes the honeycomb structure fall into pieces. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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17 pages, 7811 KiB

Open AccessArticle

Characterization of Heterogeneous Microstructure and Mechanical Properties of Q345R Welded Joints including Roles of the Welding Process

by Qingkun He, Xiaodong Hu, Qitong Sun, Zhilong Dong, Xuefang Xie and Han Wang

Metals 2022, 12(10), 1708; https://doi.org/10.3390/met12101708 - 12 Oct 2022

Cited by 1 | Viewed by 1336

Abstract

In this paper, the roles of the welding process on the heterogeneous microstructure and mechanical properties of Q345R welded joints were analyzed by a series of tests, including the preparation of welded joints with different welding processes, optical microscope observation, uniaxial tensile tests, and hardness and impact measurements. The experimental results show that with the increase in welding heat input, the content of pre-eutectoid ferrite and the size of the Weidner structure increased, while the hardness and the impact absorption energy of the weld zone decreased gradually. With the increase in heat input, the volume proportion of eutectoid ferrite in the weld increased from 9.90% to 18.78%; the volume proportion of acicular ferrite decreased from 85.10% to 76.21%. With the decrease in heat input, the volume proportion of eutectoid ferrite decreased from 10.58% to 1.45%, and the volume proportion of acicular ferrite increased from 84.21% to 92.74%. Under the influence of the second welding heat, the first weld zone, the fusion zone and part of the heat-affected zone were re-austenitizing, and the distribution of ferrite and pearlite was more uniform. The hardness value of the former weld was lower than that of the second weld, and the distribution was more uniform. The maximum hardness value of the second weld zone and its corresponding heat-affected zone increased with the increase in depth. The distribution of the yield strength and the tensile strength of welded joints was similar to that of hardness. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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14 pages, 5493 KiB

Open AccessArticle

Control of Welding Residual Stress in Large Storage Tank by Finite Element Method

by Gang Wu, Jinheng Luo, Lifeng Li, Yan Long, Shuxin Zhang, Yujie Wang, Yao Zhang and Shuyi Xie

Metals 2022, 12(9), 1502; https://doi.org/10.3390/met12091502 - 10 Sep 2022

Cited by 3 | Viewed by 1950

Abstract

T-joint welding is a key manufacturing process of large storage tanks. However, complex residual stresses are generated and have a great effect on the structural integrity of storage tanks. The high residual stress caused by welding and the discontinuous structure may result in tank cracking and failure. In this work, the residual stress distributions on the inner surface, outer surface, and thickness direction of the T-joint were investigated by using the finite element method and indentation test method. The effect of local PWHT with different heating temperatures, heating rates, and heating widths on the residual stress distribution was also discussed. Results show that the residual stress of the T-shaped joint is high due to the serious structure discontinuity, multi-layer welding, and high strength. Among all the stresses, the circumferential residual stress is the highest and most concentrated in the outer weld connected with the annular plate. The residual stress gradually decreases with the increase in the heat treatment temperature. When the heating rate is less than 106 °C/h, the residual stress gradually decreases with the decrease in the heating rate. The large thermal deformation caused by heat treatment can be simultaneously avoided by heating the inside and outside of the T-joint. The residual stress decreases with the decrease in the width of the heating zone. The residual stress can be regulated by using a smaller width in the heating zone. An optimized heat treatment scheme with a heating temperature of 700 °C, heating rate of 56 °C/h, and heating width of 200 mm was proposed, which has a good ability to control residual stresses and improve the quality of the T-joint. It also has a good application in engineering. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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11 pages, 3008 KiB

Open AccessArticle

Binary Newton Calculation Method of Residual Stress Based on the Indentation Energy Difference Theory

by Desheng Kong, Bin Yang and Peiyu Hu

Metals 2022, 12(9), 1439; https://doi.org/10.3390/met12091439 - 29 Aug 2022

Viewed by 1283

Abstract

Residual stress is a key parameter to evaluate the structural reliability of energy equipment. The indentation method has the characteristics of being nondestructive and easy to operate to calculate the residual stress of test materials, which has a broad application prospect in the field testing of energy equipment. However, because of the effect of preloading and data acquisition delay, the problem of indentation data fluctuation is prominent, and the indentation energy coefficient fitted by the traditional least square method is not consistent with the theoretical law, making it difficult to carry out stable calculations. In this paper, the Newton iteration formula of a binary nonlinear formula is derived based on the univariate Newton iteration formula, which is introduced into the data processing of residual stress, which increases the weight of the data in the stability stage and reduces the influence of the fluctuation data on the fitting results, so that the indentation energy coefficient is accurately calculated. Combined with the basic principle of indentation energy difference theory, the precise and efficient measurement of residual stress is realized. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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18 pages, 7522 KiB

Open AccessArticle

Micromechanics-Based Low Cycle Fatigue Life Prediction Model of ECAPed Aluminum Alloy

by Teng Sun, Yiji Xie, Yuchen Pan, Zhanguang Zheng, Changji Xie and Zeng Huang

Metals 2022, 12(7), 1127; https://doi.org/10.3390/met12071127 - 30 Jun 2022

Cited by 2 | Viewed by 1391

Abstract

Ultrafine-grained aluminum alloys (UFG AA) show great potential in the design of fatigue-resistant lightweight alloys, and the methodology to assess low-cycle fatigue (LCF) life remains to be studied. In this work, a micromechanics-based LCF life prediction model is presented by conducting crystal plasticity finite element simulation (CPFEM). The fatigue indicator parameter (FIP) of maximum accumulated equivalent plastic strain energy, modulated by triaxiality, is developed to assess the material damage in the microstructure. Particularly, a new multiaxial strain parameter is proposed by considering the combined influence of the mean strain and non-proportional cyclic additional hardening effect, and then directly embedding into the cyclic J-integral. Finally, the reformulated Manson-Coffin relationship is theoretically constructed by correlating the crack tip opening displacement to the crack propagation equation. The results show the scatter fatigue life of UFG AA6061 is not only related to the inhomogeneous evolution of plastic deformation but also to the local stress state. Since the proposed approach considers both the deformation mechanisms at the micro-scale and the corresponding macroscopic responses, it can predict the LCF life of UFG AA with reasonable accuracy. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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17 pages, 9953 KiB

Open AccessArticle

Studies of High-Temperature Fatigue Behavior and Mechanism for Nickel-Based Superalloy Inconel 625

by Zhenxing Wu, Xuedong Chen, Zhichao Fan, Yu Zhou and Jie Dong

Metals 2022, 12(5), 755; https://doi.org/10.3390/met12050755 - 28 Apr 2022

Cited by 4 | Viewed by 2262

Abstract

Strain-controlled continuous fatigue and creep–fatigue tests were carried out at 700 °C and 800 °C on Inconel 625 alloy. The effects of strain rate and tensile-hold time on cyclic stress response and fatigue life were investigated. Then, the microstructural analysis and the fractographic analysis of fatigue-fractured specimens were performed by scanning electron microscopy and transmission electron microscopy. The cyclic stress responses during high-temperature fatigue and the creep–fatigue–oxidation damage mechanism were discussed. The results showed that the strain rate and the tensile-hold time had little effect on the fatigue life at 700 °C, but there was a significant impact at 800 °C due to the creep–fatigue–oxidation interaction. The cyclic plastic deformation accelerated the precipitation of the γ″ phase, resulting in a continuous cyclic hardening and negative strain rate sensitivity. The fatigue failures at 700 °C under continuous fatigue conditions occurred with a transgranular fracture mode, while a transgranular-intergranular hybrid fracture manner was found at 800 °C. Furthermore, a frequency-modified total strain energy density model was proposed to consider the effects of creep and oxidation on fatigue life, and the predicted fatigue lives were located within the 1.5 times error band. Full article

(This article belongs to the Special Issue Residual Stress and Fatigue of Metals)

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