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Autofrettage

Autofrettage is a process that creates residual internal stresses in a component through plastic deformation. It involves pressurizing a component beyond its yield strength which plastically deforms the inner surface while elastically deforming the deeper areas. This results in compressive stresses near the inner surface and tensile stresses deeper within the material. These residual stresses allow a component to withstand higher working pressures without failure and increase fatigue life. Autofrettage provides benefits such as reducing the need for high strength materials, allowing thinner wall thicknesses, increasing maximum working pressures, decreasing stress concentrations around holes, and arresting crack propagation.

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Janardhan Reddy
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225 views4 pages

Autofrettage

Autofrettage is a process that creates residual internal stresses in a component through plastic deformation. It involves pressurizing a component beyond its yield strength which plastically deforms the inner surface while elastically deforming the deeper areas. This results in compressive stresses near the inner surface and tensile stresses deeper within the material. These residual stresses allow a component to withstand higher working pressures without failure and increase fatigue life. Autofrettage provides benefits such as reducing the need for high strength materials, allowing thinner wall thicknesses, increasing maximum working pressures, decreasing stress concentrations around holes, and arresting crack propagation.

Uploaded by

Janardhan Reddy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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White Paper Autofrettage

What is meant by autofrettage and what


happens inside the component?
Autofrettage is a process that creates an internal

After relieving the autofrettage pressure from the

stress in a component, similar to the shot blasting.

component, the elastically formed areas try to

Autofrettage is used in most cases for the inner

return to their original state while the plastically

pressure active components without (tubes) and

formed areas prevent this process. Therefore

with cross borings (rails).

internal stresses are created in a huge part of the


wall thickness which tries to work against the

When

component

is

pressurized

by

an

stresses that arise from normal working pressure.

autofrettage pressure, which is much higher than


the working pressure and is dependent on the

Under working pressure the stresses inside the

material used, hardness, and the geometry of the

component do not move between 0 and a maximal

component, the inner boring will be formed

value any more, but start in the pressure area

plastically and the deeper areas of the component

below 0 and end at a much lower maximal value.

wall will be formed elastically.


Pressure Time Table

with

Tube
(pressurized)

without

Stress Table

without

max. stress without Autofrettage


max. stress with Autofrettage

with

Picture 1

MAXIMATOR Test, LLC + 1350 Tri State Packway, Suite 130 + Gurnee, IL 60031 + p 847.855.2700 + e info@maximator-test.com

As you can see from picture 1, the resulting

If autofrettaged after bending, the internal

working loads (e. g. in the pipe) can be reduced

stresses of autofrettage will overlie or neutralize

considerably.

the

internal

stresses

and

the

effects

of

autofrettage will be lost.


A working pressure which would have led to a
failure of the component prior to autofrettage can

If you have components with cross cutting there

now be used endlessly at least for a

will be an additional effect: On those areas

considerably longer time without failure. This

around

can lead the design engineer to look for cost

concentration.

the

drill

hole

there

is

stress

saving strategies (i.e. material selection, material


Therefore these are the weak sections inside a

reduction etc.).

component. Cracks in this part are very often the


If you want to use the same positive effects of

reason for failure. If you have high dynamic

autofrettage for bent pipes, the autofrettage has

working pressures even the autofrettage cannot

to be done after the bending.

prevent a crack in these cross cuttings.

Stressloads after autofrettage which


are acting against each other

Picture 2: Simplified view of stress loads after autofrettage

MAXIMATOR Test, LLC + 1350 Tri State Packway, Suite 130 + Gurnee, IL 60031 + p 847.855.2700 + e info@maximator-test.com

The crack will just grow up to a certain length

As the pressures of autofrettage are calculated in

and will then be stopped by the pressure internal

that way that a huge part of the wall thickness is

stresses that are inside the wall, picture 3.

plastic, the pressure does not have to be


reached with absolute exactness.

The internal stresses press the crack together.


To receive the requested internal stresses by an

Which deviations are acceptable and which not,

autofrettage, the pressure of the autofrettage just

depends on every single case. The autofrettage

has to be held a short time.

of a component in more than just one case


should be avoided.

A longer time does not increase the internal


stresses inside the component, but leads to a
strong widening of the inner boring.

Crack

Stress loads which were influenced during


autofrettage are pressing the crack
together. The crack doesn`t grow anymore

Picture 3: Stress load prevents crack propagation

MAXIMATOR Test, LLC + 1350 Tri State Packway, Suite 130 + Gurnee, IL 60031 + p 847.855.2700 + e info@maximator-test.com

Summarization
What are the advantages?
The following effects can be received by
autofrettage:

The following improvements can be achieved:


The working pressure stays the same - the

The working pressure that could be held by

the autofrettaged components without failure,


increases. (with pipes up to 1.8 times higher,
with components with cross boring up to 2.5

wall thickness can be reduced.


The working pressure stays the same -

cheaper material can be used.


In general there is the possibility to increase

the working pressure.

times higher)

The finishing of borings and surfaces can be


The spreading of the achievable pressure

changing numbers in the time solidity area of


the Whler line decreases. That means the
fracture pressure changing numbers on the

eliminated eventually.
The life time of a component can be

increased at a corresponding working


pressure.

pressure horizon, where the autofrettage


components fail, come next to each other.
The spreading is the proportion of the

pressure changing numbers N90% (90% of


all parts survive) to N10% (10% of all parts
survive). Non-autofrettage parts have in
general a spreading of T=1,3. Autofrettage
components had in tests a spreading of
T<=1,1.
The notch sensitivity decreases strongly.

For further information please consult


www.maximator-test.com

MAXIMATOR Test, LLC + 1350 Tri State Packway, Suite 130 + Gurnee, IL 60031 + p 847.855.2700 + e info@maximator-test.com

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