Measurement of residual stresses in dissimilar friction stir-welded aluminium and copper plates using the contour method

The longitudinal residual stresses in the friction stir-welded plates of 5A06 aluminium and pure copper were determined using the contour method. The results revealed the presence of high tensile and compressive residual stresses on the aluminium and copper sides, respectively. The residual stresses were detected on the weld zone as well as the thermo-mechanically affected zone (TMAZ) of the aluminium plate. In contrast, the compressive residual stresses in the copper plate had a much narrower width along the weld line. Peak tensile stresses up to 240 MPa were found in the TMAZ of the aluminium plate

Measuring Inaccessible Residual Stresses Using Multiple Methods and Superposition

The traditional contour method maps a single component of residual stress by cutting a body carefully in two and measuring the contour of the cut surface. The cut also exposes previously inaccessible regions of the body to residual stress measurement using a variety of other techniques, but the stresses have been changed by the relaxation after cutting. In this paper, it is shown that superposition of stresses measured post-cutting with results from the contour method analysis can determine the original (pre-cut) residual stresses. The general superposition theory using Bueckner’s principle is developed and limitations are discussed. The procedure is experimentally demonstrated by determining the triaxial residual stress state on a cross section plane. The 2024- T351 aluminum alloy test specimen was a disk plastically indented to produce multiaxial residual stresses. After cutting the disk in half, the stresses on the cut surface of one half were determined with X-ray diffraction and with hole drilling on the other half. To determine the original residual stresses, the measured surface stresses were superimposed with the change stress calculated by the contour method. Within uncertainty, the results agreed with neutron diffraction measurements taken on an uncut disk

Imaging Flaws in Adhesive Joints Using Acoustic Techniques and Infrared Thermography

The ability to ensure the integrity and reliability of adhesive joints is essential to increased use of lightweight materials in the automotive industry [1]. For manufacturing applications, on-line inspection techniques must be fast, accurate with limited access to parts, robust in manufacturing environments and available at reasonable cost. The work presented here is part of a project in which nondestructive techniques are being evaluated to access their ability to detect and characterize flaws in adhesive joints in metals and composite materials. The long-term goal of the project is development of a prototype on-line inspection system for automobile structural members

Measurement of the residual stress tensor in a compact tension weld specimen

Neutron diffraction measurements have been performed to determine the full residual stress tensor along the expected crack path in an austenitic stainless steel (Esshete 1250) compact tension weld specimen. A destructive slitting method was then implemented on the same specimen to measure the stress intensity factor profile associated with the residual stress field as a function of crack length. Finally deformations of the cut surfaces were measured to determine a contour map of the residual stresses in the specimen prior to the cut. The distributions of transverse residual stress measured by the three techniques are in close agreement. A peak tensile stress in excess of 600 MPa was found to be associated with an electron beam weld used to attach an extension piece to the test sample, which had been extracted from a pipe manual metal arc butt weld. The neutron diffraction measurements show that exceptionally high residual stress triaxiality is present at crack depths likely to be used for creep crack growth testing and where a peak stress intensity factor of 35 MPa√m was measured (crack depth of 21 mm). The neutron diffraction measurements identified maximum values of shear stress in the order of 50 MPa and showed that the principal stress directions were aligned to within ~20° of the specimen orthogonal axes. Furthermore it was confirmed that measurement of strains by neutron diffraction in just the three specimen orthogonal directions would have been sufficient to provide a reasonably accurate characterisation of the stress state in welded CT specimens

Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

Cutting-induced plasticity can lead to elevated uncertainties in residual stress measurements made by the contour method. In this study plasticity-induced stress errors are numerically evaluated for a benchmark edge-welded beam to understand the underlying mechanism. Welding and cutting are sequentially simulated by finite element models which have been validated by previous experimental results. It is found that a cutting direction normal to the symmetry plane of the residual stress distribution can lead to a substantially asymmetrical back-calculated stress distribution, owing to cutting-induced plasticity. In general, the stresses at sample edges are most susceptible to error, particularly when the sample is restrained during cutting. Inadequate clamping (far from the plane of cut) can lead to highly concentrated plastic deformation in local regions, and consequently the back-calculated stresses have exceptionally high values and gradients at these locations. Furthermore, the overall stress distribution is skewed towards the end-of-cut side. Adequate clamping (close to the plane of cut) minimises errors in back-calculated stress which becomes insensitive to the cutting direction. For minimal constraint (i.e. solely preventing rigid body motion), the plastic deformation is relatively smoothly distributed, and an optimal cutting direction (i.e. cutting from the base material towards the weld region in a direction that falls within the residual stress symmetry plane) is identified by evaluating the magnitude of stress errors. These findings suggest that cutting process information is important for the evaluation of potential plasticity-induced errors in contour method results, and that the cutting direction and clamping strategy can be optimised with an understanding of their effects on plasticity and hence the back-calculated stresses

Measuring multiple residual-stress components using the contour method and multiple cuts

The conventional contour method determines one component of stress over the cross section of a part. The part is cut into two, the contour of the exposed surface is measured, and Bueckner's superposition principle is analytically applied to calculate stresses. In this paper, the contour method is extended to the measurement of multiple stress components by making multiple cuts with subsequent applications of superposition. The theory and limitations are described. The theory is experimentally tested on a 316L stainless steel disk with residual stresses induced by plastically indenting the central portion of the disk. The stress results are validated against independent measurements using neutron diffraction. The theory has implications beyond just multiple cuts. The contour method measurements and calculations for the first cut reveal how the residual stresses have changed throughout the part. Subsequent measurements of partially relaxed stresses by other techniques, such as laboratory x-rays, hole drilling, or neutron or synchrotron diffraction, can be superimposed back to the original state of the body

Surface modification of starch based biomaterials by oxygen plasma or UV-irradiation

Radiation is widely used in biomaterials science for surface modification and sterilization. Herein, we describe the use of plasma and UV-irradiation to improve the biocompatibility of different starch-based blends in terms of cell adhesion and proliferation. Physical and chemical changes, introduced by the used methods, were evaluated by complementary techniques for surface analysis such as scanning electron microscopy, atomic force microscopy, contact angle analysis and X-ray photoelectron spectroscopy. The effect of the changed surface properties on the adhesion of osteoblast-like cells was studied by a direct contact assay. Generally, both treatments resulted in higher number of cells adhered to the modified surfaces. The importance of the improved biocompatibility resulting from the irradiation methods is further supported by the knowledge that both UV and plasma treatments can be used as cost-effective methods for sterilization of biomedical materials and devices.I. P. thanks the FCT for providing her a postdoctoral scholarship (SFRH/BPD/8491/2002). This work was partially supported by FCT, through funds from the POCTI and/or FEDER programs, The European Union funded STREP Project HIPPOCRATES (NNM-3-CT-2003-505758) and the European NoE EXPERTISSUES (NMP3-CT-2004-500283)

Height and timing of growth spurt during puberty in young people living with vertically acquired HIV in Europe and Thailand.

OBJECTIVE: The aim of this study was to describe growth during puberty in young people with vertically acquired HIV. DESIGN: Pooled data from 12 paediatric HIV cohorts in Europe and Thailand. METHODS: One thousand and ninety-four children initiating a nonnucleoside reverse transcriptase inhibitor or boosted protease inhibitor based regimen aged 1-10 years were included. Super Imposition by Translation And Rotation (SITAR) models described growth from age 8 years using three parameters (average height, timing and shape of the growth spurt), dependent on age and height-for-age z-score (HAZ) (WHO references) at antiretroviral therapy (ART) initiation. Multivariate regression explored characteristics associated with these three parameters. RESULTS: At ART initiation, median age and HAZ was 6.4 [interquartile range (IQR): 2.8, 9.0] years and -1.2 (IQR: -2.3 to -0.2), respectively. Median follow-up was 9.1 (IQR: 6.9, 11.4) years. In girls, older age and lower HAZ at ART initiation were independently associated with a growth spurt which occurred 0.41 (95% confidence interval 0.20-0.62) years later in children starting ART age 6 to 10 years compared with 1 to 2 years and 1.50 (1.21-1.78) years later in those starting with HAZ less than -3 compared with HAZ at least -1. Later growth spurts in girls resulted in continued height growth into later adolescence. In boys starting ART with HAZ less than -1, growth spurts were later in children starting ART in the oldest age group, but for HAZ at least -1, there was no association with age. Girls and boys who initiated ART with HAZ at least -1 maintained a similar height to the WHO reference mean. CONCLUSION: Stunting at ART initiation was associated with later growth spurts in girls. Children with HAZ at least -1 at ART initiation grew in height at the level expected in HIV negative children of a comparable age