Research Papers: Materials and Fabrication

Slitting and Contour Method Residual Stress Measurements in an Edge Welded Beam

[+] Author and Article Information
Foroogh Hosseinzadeh

 The Open University, Walton Hall, Milton Keynes, Buckinghamshire, MK7 6AAf.hosseinzadeh@open.ac.uk

Muhammed Burak Toparli

 The Open University, Walton Hall, Milton Keynes, Buckinghamshire, MK7 6AAm.b.toparli@open.ac.uk

Peter John Bouchard

 The Open University, Walton Hall, Milton Keynes, Buckinghamshire, MK7 6AAp.j.bouchard@open.ac.uk

J. Pressure Vessel Technol 134(1), 011402 (Dec 02, 2011) (6 pages) doi:10.1115/1.4004626 History: Received February 21, 2011; Revised May 05, 2011; Published December 02, 2011; Online December 02, 2011

Welding is known to introduce complex three-dimensional residual stresses of substantial magnitude into pressure vessels and pipe-work. For safety-critical components, where welded joints are not stress-relieved, it can be of vital importance to quantify the residual stress field with high certainty in order to perform a reliable structural integrity assessment. Finite element modeling approaches are being increasingly employed by engineers to predict welding residual stresses. However, such predictions are challenging owing to the innate complexity of the welding process (Hurrell , Development of Weld Modelling Guidelines in the UK, Proceedings of the ASME Pressure Vessels and Piping Conference, Prague, Czech Republic, July 26–30, 2009, pp. 481–489). The idea of creating weld residual stress benchmarks against which the performance of weld modeling procedures and practitioners can be evaluated is gaining increasing acceptance. A stainless steel beam 50 mm deep by 10 mm wide, autogenously welded along the 10 mm edge, is a candidate residual stress simulation benchmark specimen that has been studied analytically and for which neutron and synchrotron diffraction residual stress measurements are available. The current research was initiated to provide additional experimental residual stress data for the edge-welded beam by applying, in tandem, the slitting and contour residual stress measurement methods. The contour and slitting results were found to be in excellent agreement with each other and correlated closely with published neutron and synchrotron residual stress measurements when differences in gauge volume and shape were accounted for.

Copyright © 2012 by American Society of Mechanical Engineers
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Figure 1

Schematic drawing of the edge-welded beam, showing the dimensions, line, and plane of measurement, coordinate system, and the location of weld

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Figure 2

Schematic drawing of the edge-welded beam for the slitting method showing the cut of depth, a, and location, M1, of the midthickness back-face strain gauge that was aligned with the plane of the slit

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Figure 3

Distribution of measured back-face strain against cut depth

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Figure 4

Distribution of the stress intensity factor against crack length

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Figure 5

Distribution of longitudinal residual stress (averaged across the width) from top to bottom of the beam at midlength of the sample measured using the slitting method

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Figure 6

Map longitudinal stresses on the cut plane at midlength of the beam measured using the contour method (MPa)

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Figure 7

Comparison between cubic splines (5 and 7 mm knot spacing) along midthickness from bottom of the beam to the weld

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Figure 8

Comparison between cubic spline fits (5 and 7 mm knot spacing) and raw measured data across the width of the specimen at midlength

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Figure 9

Contour measurement stress results along the y-axis for 5 and 7 mm spline knot spacings

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Figure 10

Comparison of the slitting and contour longitudinal residual stresses

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Figure 11

Measured residual stresses in the edge-welded beam using different techniques. Contour results are plotted along midthickness.

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Figure 12

Comparison between the measured stresses using the contour, slitting, and synchrotron x-ray diffraction techniques. Contour results are line-averaged values across the thickness.



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