Effect of high-pressure rolling followed by laser processing on mechanical properties, microstructure and residual stress distribution in multi-pass welds of 304L stainless steel

Multi-pass fusion welding by a filler material (wire) is normally carried out to join thick steel sections used in most engineering applications. Multiple thermal cycles from a multi-pass weld resulted in a variable distribution of residual stress field across the weld and through the thickness. Presence of tensile residual stresses can be detrimental to the integrity and the service behaviour of the welded joint. In addition to a complex distribution of residual stress state, multi-pass welds also form dendritic grain structure, which are repeatedly heated, resulting in segregation of alloying elements. In this research, microstructural refinement with modification of residual stress state was attempted by applying post-weld cold rolling followed by laser processing and then cold rolling. The residual stress was determined non-destructively by using neutron diffraction. Post-weld cold rolling followed by laser processing was carried out to induce recrystallization of the cold rolled grains. Microstructural characterisation indicates a significant grain refinement near the capping pass. However, post-weld cold rolling followed by laser processing reinstates the lock-in stress. In this study, it was demonstrated that a complete recrystallized microstructure with compressive state of stress can be formed when a further cold rolling is applied on the laser processed, recrystallized microstructure

Contraintes Résiduelles dans les Billettes d’Aluminium : Mesures par Diffraction de Neutrons et Simulation Thermomécanique

Les contraintes internes qui apparaissent dans les billettes d’aluminium produites par coulée semi-continue trouvent leur origine dans le différentiel du chemin thermomécanique en coeur ou en surface de la billette et posent de sérieux problèmes de sécurité lors de la découpe. Un modèle thermomécanique de la coulée semi-continue a été validé en termes de contraintes résiduelles, ces dernières étant mesurées par diffraction des neutrons. Les composantes radiales, orthoradiales et axiales du tenseur des contraintes ont été mesurées le long du rayon d’une billette de diamètre 320 mm

Neutronographic Analysis of Load Partitioning and Micro Residual Stress Development in Duplex Stainless Steels

In the present work, neutronographic in situ diffraction stress analyses during uniaxial loading and subsequent unloading were carried out on the two duplex stainless steels X2CrNiMoN22-5-3 and X3CrNiMoN27-5-2 with nominal phase fractions for ferrite:austenite of 50:50% and 70:30%, respectively. In addition to the different phase fractions, the two steels also differed in their phase-specific crystallographic texture. The load-partitioning behaviour and the phase-specific micro (residual) stress evolution for total strains up to about 9% were investigated. The results indicated that for both materials under load, the phase-specific stress in the ferrite phase was significantly higher than in the austenite phase, while no texture development through the plastic deformation could be observed

Quantification of Residual Stresses in Electron Beam Welded Fracture Mechanics Specimens

Residual stress measurements have been made in a range of electron beam welded samples to study how the weld induced residual stresses redistributed during fabrication of compact tension, C(T), specimens. The samples were manufactured from Type 316H stainless steel in the ex-service material condition and in material which had been preconditioned by inducing 8% plastic strain. Measurements made using neutron diffraction, slitting and the contour method were generally in good agreement and showed residual stress components of up to three times the base material's yield strength existed in the samples. When sectioning a sample to perform the contour method, large elastic deformations occurred at the cut tip due to the large residual stresses present. A correction was applied to the measured surface displacements to account for this deformation. Neutron diffraction measurements were made at various stages of the fabrication process, which showed significant stress redistribution occurred as the welded samples were machined into C(T) specimens. However the tensile stresses near the crack tip of the C(T) specimens remained large and could significantly influence subsequent crack growth tests

Determination of Coherency and Rigidity Temperatures in Al-Cu Alloys Using In Situ Neutron Diffraction During Casting

The rigidity temperature of a solidifying alloy is the temperature at which the solid phase is sufficiently coalesced to transmit tensile stress. It is a major input parameter in numerical modeling of solidification processes as it defines the point at which thermally induced deformations start to generate internal stresses in a casting. This temperature has been determined for an Al-13wt.% Cu alloy using in situ neutron diffraction during casting in a dog-bone-shaped mold. This setup allows the sample to build up internal stress naturally as its contraction is not possible. The cooling on both sides of the mold induces a hot spot at the middle of the sample that is irradiated by neutrons. Diffraction patterns are recorded every 11s using a large detector, and the very first change of diffraction angles allows for the determination of the rigidity temperature. We measured rigidity temperatures equal to 557°C and 548°C depending on the cooling rate for grain refined Al-13wt.% Cu alloys. At a high cooling rate, rigidity is reached during the formation of the eutectic phase. In this case, the solid phase is not sufficiently coalesced to sustain tensile load and thus cannot avoid hot tear formation

Heterogeneity of Graphite Lithiation in State‐of‐the‐Art Cylinder‐Type Li‐Ion Cells

The two‐dimensional lithium distribution in the graphite anode was non‐destructively probed by spatially resolved neutron diffraction for a batch consisting of 34 different cylinder‐type (18650) Li‐ion batteries in fully charged state. The uniformity of the lithium distribution was quantified and correlated to the cell specifications/electrochemistry and to intrinsic cell parameters like electrode thickness, position of current collectors, etc. which were obtained by X‐ray micro‐computed tomography. Non‐uniformities in the lithiation state of the anode from a constant plateau have been observed for the majority of the studied cells. Their location corresponds to the positions of current tabs connecting the electrode stripes and areas of incomplete electrode coating at the beginning and the end of the electrode stripes. Four commonly used schemes of current lid connection were identified. Each of them displays its own effect on the uniformity of the lithiation at the anode and, therefore, variation of the intrinsic state‐of‐charge distribution and, most probably, the ageing behavior of the electrodes

Determination of Coherency and Rigidity Temperatures in Al-Cu Alloys Using In Situ Neutron Diffraction During Casting

The rigidity temperature of a solidifying alloy is the temperature at which the solid phase is sufficiently coalesced to transmit tensile stress. It is a major input parameter in numerical modeling of solidification processes as it defines the point at which thermally induced deformations start to generate internal stresses in a casting. This temperature has been determined for an Al-13 wt.% Cu alloy using in situ neutron diffraction during casting in a dog-bone-shaped mold. This setup allows the sample to build up internal stress naturally as its contraction is not possible. The cooling on both sides of the mold induces a hot spot at the middle of the sample that is irradiated by neutrons. Diffraction patterns are recorded every 11 s using a large detector, and the very first change of diffraction angles allows for the determination of the rigidity temperature. We measured rigidity temperatures equal to 557C and 548C depending on the cooling rate for grain refined Al-13 wt.% Cu alloys. At a high cooling rate, rigidity is reached during the formation of the eutectic phase. In this case, the solid phase is not sufficiently coalesced to sustain tensile load and thus cannot avoid hot tear formation

A comparative study of additive manufacturing techniques: Residual stress and microstructural analysis of CLAD and WAAM printed Ti-6Al-4V components

Nowadays, there is a great manufacturing trend in producing higher quality net-shape components of challenging geometries. One of the major challenges faced by additive manufacturing (AM) is the residual stresses generated during AM part fabrication often leading to unacceptable distortions and degradation of mechanical properties. Therefore, gaining insight into residual strain/stress distribution is essential for ensuring acceptable quality and performance of high-tech AM parts. This research is aimed at comparing microstructure and residual stress built-up in Ti–6Al–4V AM components produced by Wire + Arc Additive Manufacturing (WAAM) and by laser cladding process (CLAD)