Papers by Author: Jens Altenkirch

Abstract: Residual stresses in welds are of major concern for the structure integrity assessment in industrial components. The stresses in the final weld can be determined relatively simple using well established destructive or non-destructive techniques. However, such measurements reflect only the final condition and it remains unclear how stresses built up during the welding process. In order to optimise the final residual stresses in the weld, it is important to monitor the formation of residual strain and stress during the welding process and as such to gain insight into the mechanisms of stress development. In this work non-destructive high energy dispersive synchrotron X-ray diffraction at a high count rate is applied in order to dissolve the welding process in-situ in time and temperature. However, the achievable time resolution at commonly used instruments is restricted by either a limited photon flux or the read out electronics of the detector system resulting in counting times usually much longer than 1sec. We present an energy dispersive detector and read-out-electronics setup realized at the high flux and energy beam line ID15A at the ESRF. The setup allowed for monitoring the strain evolution in two perpendicular directions simultaneously at a sampling rate of 5Hz, resulting in sufficient time and temperature resolution. The change in detector dead time is accounted for by a correction function, which was specifically determined for the detector setup as used for this in-situ experiment.

Abstract: Low Transformation Temperature (LTT) alloys were developed in order to control the residual stress development by the martensitic phase transformation already during cooling of the weld metal. The positive effect of such LTT alloys on the mitigation of detrimental tensile residual stresses during welding has already been confirmed on the basis of individual laboratory tests. Within the current project it was experimentally investigated whether the phase transformation mechanisms are effective under increased restraint due to multi-pass welding of thicker specimens. The local residual stress depth distribution was analyzed non-destructively for V-type welds processed by arc welding using energy dispersive synchrotron X-ray diffraction (EDXRD). The use of high energy (20 keV to 150 keV) EDXRD allowed for the evaluation of diffraction spectra containing information of all contributing phases. As the investigated LTT alloy contains retained austenite after welding, this phase was also considered for stress analysis. The results show in particular how the constraining effect of increased thickness of the welded plates and additional deposited weld metal influences the level of the residual stresses in near weld surface areas. While the longitudinal residual stresses were reduced in general, in the transition zone from the weld to the heat-affected zone (HAZ) compressive residual stresses were found.