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Proto - Welds - Application - iXRD

This document discusses residual stress mapping techniques for welds. It describes how residual stresses created during welding can lead to issues like cracking and premature failure. X-ray diffraction is presented as a useful nondestructive technique for characterizing residual stresses in welds to optimize welding processes and failure analysis. The document also outlines applications of residual stress measurement like evaluating stress concentrations, fatigue life, and validating finite element models of welds. Post-weld processes like heat treating, shot peening, and machining are discussed as ways to manage residual stresses, and the benefits of residual stress characterization are highlighted.

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celestino biasotto
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64 views4 pages

Proto - Welds - Application - iXRD

This document discusses residual stress mapping techniques for welds. It describes how residual stresses created during welding can lead to issues like cracking and premature failure. X-ray diffraction is presented as a useful nondestructive technique for characterizing residual stresses in welds to optimize welding processes and failure analysis. The document also outlines applications of residual stress measurement like evaluating stress concentrations, fatigue life, and validating finite element models of welds. Post-weld processes like heat treating, shot peening, and machining are discussed as ways to manage residual stresses, and the benefits of residual stress characterization are highlighted.

Uploaded by

celestino biasotto
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Patented Automated

Residual Stress Mapping

WELDS
X-ray Diffraction Residual Stress Measurement
MEASURING RESIDUAL STRESS IN WELDS
Residual stresses created during the welding process can lead to stress corrosion
cracking, distortion, fatigue cracking, premature failures in components, and instances
of over design. The nondestructive nature of the x-ray diffraction technique has made
the residual stress characterization of welds a useful tool for process optimization and
failure analysis, particularly since components can be measured before welding, after
welding and after post-welding processes.

MANAGING RESIDUAL STRESS IN WELDS


Numerous techniques such as heat treating and shot
peening are available to help manage potentially
Residual Stress (ksi)
+40 harmful residual stresses created during the welding
+20
0 process. Knowledge of the residual stress state is
-20
-40 required to ensure that these post welding processes
Friction StirWelded Aluminum Plate have been correctly applied.
REAL DATA
NOT
MODELLING

Example of a residual stress


multi-map with a third
“difference” map plotted
by applying map algebra to
the first two maps collected
on the same weld before
and after the weld was
partially shot peened. This
map overlaps the interface
where the weld was shot
peened and masked (i.e.
not shot peened).

Example of a residual stress map on a


partially peened weld.

RESIDUAL STRESS MAPPING 200

PROTO’S patented Automated Residual -200

Stress Mapping technology can generate a -400

comprehensive picture of the residual stress -600

-800
state of any sample. Even curved surfaces -1000

such as welds can be automatically mapped -1200

allowing designers and engineers to visualize


0.00 .2 0.40 .6 0.81 .0

and manage problem areas.


Example of a residual stress vs. depth
distribution for different peening
conditions.
RESIDUAL STRESS MEASUREMENT APPLICATIONS

FATIGUE LIFE AND STRESS CONCENTRATIONS 80

70
Weld Edges

60

Stress (ksi)
The residual stress state in weld toes and undercuts are critical 50

when stress concentration geometries exist that can magnify 40

30

the effects of applied loads. When issues of fatigue cracking are 20

considered, potentially harmful tensile residual stresses alone or in 10


-0.4 -0.3 -0.2 -0.1 00 .1 0.20 .3 0.4

combination with stress.concentrations can lead to fatigue crack Distance From Weld Centerline (inches)

initiation and propagation. Electron Beam Welded Inconel

Tensile STRESS CORROSION CRACKING (SCC)


Stress
Heat treatment processes are also commonly applied to welds to
SCC lower or reduce the residual stresses present in the weld and HAZ.
Susceptible Corrosive
Material Environment Residual stress measurement can be used to ensure that such
processess have been correctly applied and that any harmful
Conditions For SCC
residual stresses have been reduced to an acceptable level.

100

80

FINISH MACHINING 60

40

Stress (ksi)
Aggressive or abusive post-welding machining can create regions 20

of tensile stress that can make the weld area susceptible to crack -20 Weld

initiation and increase the rate of crack propagation. -40

-60
Parent

00 .010 .020 .030 .04

Depth (inches)

Residual Stress with Depth


POST-WELD PROCESSES
An effective way to manage the residual stresses in welds is to cold work the weld using a
process such as shot peening. Residual stress measurements can be performed to ensure that
tensile residual stresses have been reduced and beneficial compressive residual stresses have
been introduced.

VALIDATION OF FINITE ELEMENT MODELS


Much time and effort is spent modeling the residual stress state of welds. Residual stress measurement
can be used to verify that these models are correct and improve models that have deficiencies.

DESIGN IMPROVEMENTS
Utilizing a “Design to RS, Produce to RS and Manage to RS”
philosophy helps to achieve reduced component weight,
improve life expectancy and lower manufacturing and
maintenance costs.
RESIDUAL STRESS PRODUCT LINE
At PROTO we offer an extensive range of
residual stress XRD products to ensure that
the most suitable equipment is available
for your measurement needs. Choose from
our high-speed LXRD Laboratory Systems,
flexible iXRD Portable Systems or our Ultra
Portable mXRD System.

PORTABLE & ULTRA PORTABLE

LABORATORY

A WORLD OF SOLUTIONS
www.protoxrd.com
1-800-965-8378

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