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Metals
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Experimental, Modeling and Simulation of Residual Stress in Metallic and...
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Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (31 July 2023) | Viewed by 12168

Special Issue Editors

Prof. Dr. Joao Nobre

E-Mail Website
Guest Editor
Department of Physics, University of Coimbra, Rua Larga à Universidade, 3004-516 Coimbra, Portugal
Interests: mechanical behaviour of materials; residual stress measurements using the hole-drilling and X-ray diffraction techniques; drilling process optimization for improving functional performance and life of high strength-to-weight ratio materials; residual stress determination in composite laminates
Special Issues, Collections and Topics in MDPI journals
Dr. Tao Wu

E-Mail Website
Guest Editor
Department of Mechanical Science and Engineering, Technical University of Dresden, 01069 Dresden, Germany
Interests: mechanical behavior of materials; finite element analysis; structural dynamics; construction; structural analysis; finite element modeling; fe analysis; solid mechanics; mechanics of materials; stress analysis

Special Issue Information

Dear Colleagues,

Residual stress can have detrimental or beneficial effects on the mechanical behavior of materials. Its evaluation, prediction/modeling and control in engineering materials assume, therefore, particular importance. This Special Issue of Metals is devoted to new advancements on measurement techniques and modeling and prediction of residual stresses in all kinds of metals: alloys, metal matrix composites, and hybrid metal–composite materials. Due to the increased demand of some key industries, such as automobile, aeronautical, and aerospace, in new materials and manufacturing processes, residual stresses related to additive manufacturing processes and hybrid metal–composite materials will be highlighted. However, residual stresses related to all manufacturing processes, surface treatments, and coatings will be covered. New developments in the understanding of the relationship between residual stresses and material properties and mechanical behavior are of great interest. Possible topics include experimental techniques and methods, genesis of residual stresses by manufacturing and processing of materials, simulation of stress profiles, texture–stress relationships, micro-meso-macro strain studies, residual stresses, and phase transformations.

Prof. Dr. Joao Nobre
Dr. Tao Wu
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 stresses
  • residual stress measurement techniques
  • additive manufacturing
  • hybrid composite materials
  • manufacturing processes
  • surface treatments
  • coatings
  • finite element analysis
  • modeling and simulation

Published Papers (6 papers)

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Research

21 pages, 4733 KiB  
Article
Numerical Investigation of Residual Stress Formation Mechanisms in Flash-Butt Welded Rail
by Kotchaporn Thadsoongnoen, Anat Hasap, Nitikorn Noraphaiphipaksa and Chaosuan Kanchanomai
Metals 2023, 13(8), 1359; https://doi.org/10.3390/met13081359 - 28 Jul 2023
Viewed by 1433
Abstract
For the construction of long and continuous railway lines as well as the replacement of defected rails, rails are joined using flash-butt welding. Under various localized temperatures and thermo-mechanical stresses, a residual stress can develop in the flash-butt welded joint. The residual stress [...] Read more.
For the construction of long and continuous railway lines as well as the replacement of defected rails, rails are joined using flash-butt welding. Under various localized temperatures and thermo-mechanical stresses, a residual stress can develop in the flash-butt welded joint. The residual stress can affect the performance and reliability of the welded rail, particularly in terms of progressive structural damage caused by repeated wheel load. In the present work, the mechanisms of residual stress formation in a flash-butt welded rail and the influence of upsetting force (including its temperature range and magnitude) were investigated using the thermal elastic–plastic finite element analysis. The formation mechanisms of residual stress involved the changes in thermal expansion coefficient, strain, and elastic modulus of the welded joint with respect to temperature. The calculated cooling temperatures and residual stresses in the flash-butt welded joint were in good agreement with the measured results. Compressive residual stresses were observed around the rail head and the rail foot (i.e., approximately −648 MPa at the rail head and −495 MPa at the rail foot), while tensile residual stresses were observed at the rail web (i.e., approximately 165 MPa). It was observed that the investigated compressive upsetting force predominantly induced plastic deformation within the welded joint, resulting in minimal alteration of stress. Consequently, the investigated ranges of upsetting temperature and upsetting forces had an insignificant impact on the formation of residual stress. Full article
(This article belongs to the Special Issue Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials)
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27 pages, 8152 KiB  
Article
Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring
by Bianhong Li, Yushuang Dong and Hanjun Gao
Metals 2023, 13(7), 1187; https://doi.org/10.3390/met13071187 - 26 Jun 2023
Viewed by 856
Abstract
Large aluminum alloy ring forgings are the core components of heavy-duty rocket fuel storage tanks, and the large residual stress inside the rings leads to poor shape accuracy of large thin-walled parts. The initial stress of the 2219 aluminum alloy ring blank was [...] Read more.
Large aluminum alloy ring forgings are the core components of heavy-duty rocket fuel storage tanks, and the large residual stress inside the rings leads to poor shape accuracy of large thin-walled parts. The initial stress of the 2219 aluminum alloy ring blank was tested using the drilling method, and the creep constitutive coefficient of the 2219 aluminum alloy was determined through stress relaxation tests. The numerical simulation processes of thermal stress relief (TSR), vibration stress relief (VSR), and thermal–vibration stress relief (TVSR) were compared and established. Through the correlation analysis between the actual measurement results of residual stress and the simulation results, it can be seen that the strong correlation in three directions at each measurement point accounts for over 37.5%, and the moderate correlation accounts for over 62.5%. This indicates that the numerical simulation model of 2219 aluminum alloy ring containing initial residual stress can accurately reflect the size and distribution of residual stress inside the actual ring. The simulation results show that the derived constitutive model can describe the stress relaxation process of TVSR by combining a single thermal time effect stress relaxation constitutive theory with a VSR plastic deformation material model. The simulation models established above were used to calculate the residual stress homogenization ability of three types of aging. The results showed that VSR, TSR, and TVSR can homogenize and reduce the residual stress field inside the ring, improve the distribution of residual stress inside the ring, and have a better overall homogenization ability of TVSR. The VSR control has a certain effect on reducing and homogenizing residual stress, but compared with TSR and TVSR, the reduction and homogenization ability of residual stress control is limited. The homogenization control effect TVSR > TSR > VSR, and the maximum equivalent stress homogenization rates of VSR, TSR, and TVSR are 52.8%, 80.6%, and 82.2%, respectively. Then, numerical simulation technology was used to study how the initial residual stress in the blank causes the deformation of the ring during the thin-walled machining process. The roundness error theory of the minimum containment area method was applied to evaluate the deformation degree during the thin-walled numerical machining process, and the TVSR method was used for stress regulation. The deformation law of the thin-walled machining of the ring under different aging parameters was studied. Full article
(This article belongs to the Special Issue Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials)
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14 pages, 6364 KiB  
Article
Monte-Carlo-Assisted Phase Field Simulations of Grain Structure Evolution during the Welding Process
by Ying Zheng, Jiangping Liu, Yongfeng Liang and Pingping Wu
Metals 2023, 13(3), 623; https://doi.org/10.3390/met13030623 - 20 Mar 2023
Viewed by 1288
Abstract
A Monte-Carlo-assisted phase field model for the simulation of grain growth in metals and alloys is presented. The simulation time in this model is connected to real time through an experimental data-based kinetic model. Site selection probability is introduced to simulate grain structure [...] Read more.
A Monte-Carlo-assisted phase field model for the simulation of grain growth in metals and alloys is presented. The simulation time in this model is connected to real time through an experimental data-based kinetic model. Site selection probability is introduced to simulate grain structure evolution under non-isothermal conditions. The grain evolutions with temporal and spatial distributions of temperature during the welding process are comprehensively reproduced. The average size and topological texture of the generated grains in the fusion zone and heat-affected zone are examined. The computed results are compared to experimental data for laser-welding two alloys: Fe–6.5 wt.%Si and low-carbon steel. The applications of real-time–temperature based phase field simulation to material processing indicate significant promise for understanding grain structures during the welding process or additive manufacturing processes. Full article
(This article belongs to the Special Issue Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials)
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17 pages, 7282 KiB  
Article
Crankshaft HCF Research Based on the Simulation of Electromagnetic Induction Quenching Approach and a New Fatigue Damage Model
by Songsong Sun, Weiqiang Liu, Xingzhe Zhang and Maosong Wan
Metals 2022, 12(8), 1296; https://doi.org/10.3390/met12081296 - 31 Jul 2022
Cited by 3 | Viewed by 1229
Abstract
In recent decades, the electromagnetic induction quenching approach has been widely applied in the surface treatment process of steel engine parts such as crankshafts. In this paper, the strengthening effect of this approach was selected to be the object of study. First, the [...] Read more.
In recent decades, the electromagnetic induction quenching approach has been widely applied in the surface treatment process of steel engine parts such as crankshafts. In this paper, the strengthening effect of this approach was selected to be the object of study. First, the multi-physics coupling phenomenon was established by a 3D finite element simulation approach. Then, the fatigue property of the crankshaft was predicted based on the combination of the residual stress field obtained in the previous step and a chosen multi-axial fatigue damage model. Finally, a corresponding experiment verification was carried out to check the accuracy of the prediction. The results showed that the method proposed by this paper can provide high enough accuracy in predicting the fatigue property of two types of commonly used steel crankshafts. Full article
(This article belongs to the Special Issue Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials)
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20 pages, 6222 KiB  
Article
Influence of Deposition Strategies on Residual Stress in Wire + Arc Additive Manufactured Titanium Ti-6Al-4V
by Bilal Ahmad, Xiang Zhang, Hua Guo, Michael E. Fitzpatrick, Leonor MacHado Santos Carvalho Neto and Stewart Williams
Metals 2022, 12(2), 253; https://doi.org/10.3390/met12020253 - 28 Jan 2022
Cited by 17 | Viewed by 3159
Abstract
Wire + arc additive manufacturing (WAAM) is a modern manufacturing process that has opened new possibilities for rapid builds and reductions in material wastage. This paper explores residual stress in WAAM Ti-6Al-4V walls built using three different deposition strategies: single bead, parallel path, [...] Read more.
Wire + arc additive manufacturing (WAAM) is a modern manufacturing process that has opened new possibilities for rapid builds and reductions in material wastage. This paper explores residual stress in WAAM Ti-6Al-4V walls built using three different deposition strategies: single bead, parallel path, and oscillation path. The effect of interlayer hammer peening and interlayer temperature was investigated for the single bead walls. We also examined the residual stress in compact-tension (C(T)) coupons extracted from large builds (walls) with crack orientation either parallel with or perpendicular to the build direction. This type of sample is often used for the measurement of the fatigue crack growth rate. The contour method was used for experimental determinations of residual stress. In addtion, residual stress in the C(T) coupons was estimated by finite element (FE) analysis. A good agreement was achieved between the contour method and FE analysis. The oscillation-path wall had the lowest residual stress values. For the single bead walls built with various process conditions, residual stress was significantly reduced after removing the substrate. A interlayer temperature of 110 °C resulted in much higher residual stress values in the wall (both tensile and compressive) compared to the continuous build, with much higher interlayer temperature. Full article
(This article belongs to the Special Issue Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials)
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19 pages, 6990 KiB  
Article
Comparative Multi-Modal, Multi-Scale Residual Stress Evaluation in SLM 3D-Printed Al-Si-Mg Alloy (RS-300) Parts
by Eugene S. Statnik, Fatih Uzun, Svetlana A. Lipovskikh, Yuliya V. Kan, Sviatoslav I. Eleonsky, Vladimir S. Pisarev, Pavel A. Somov, Alexey I. Salimon, Yuliya V. Malakhova, Aleksandr G. Seferyan, Dmitry K. Ryabov and Alexander M. Korsunsky
Metals 2021, 11(12), 2064; https://doi.org/10.3390/met11122064 - 20 Dec 2021
Cited by 8 | Viewed by 3077
Abstract
SLM additive manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in the aerospace industry. The importance [...] Read more.
SLM additive manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in the aerospace industry. The importance of the evaluation of residual stresses that arise as a result of the 3D-printing process’ complex thermal history is widely discussed in literature, but systematic assessment remains lacking for their magnitude, spatial distribution, and comparative analysis of different evaluation techniques. In this study, we report the results of a systematic study of residual stresses in 3D-printed double tower shaped samples using several approaches: the contour method, blind hole drilling laser speckle interferometry, X-ray diffraction, and Xe pFIB-DIC micro-ring-core milling analysis. We show that a high level of tensile and compressive residual stresses is inherited from SLM 3D-printing and retained for longer than 6 months. The stresses vary (from −80 to +180 MPa) over a significant proportion of the material yield stress (from −⅓ to ¾). All residual stress evaluation techniques considered returned comparable values of residual stresses, regardless of dramatically different dimensional scales, which ranged from millimeters for the contour method, laser speckle interferometry, and XRD down to small fractions of a mm (70 μm) for Xe pFIB-DIC ring-core drilling. The use of residual stress evaluation is discussed in the context of optimizing printing strategies to enhance mechanical performance and long-term durability. Full article
(This article belongs to the Special Issue Experimental, Modeling and Simulation of Residual Stress in Metallic and Composite Materials)
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