Papers by Author: Joana Rebelo-Kornmeier

Abstract: The cooling of the material during elastic tensile loading is well known as the thermoelastic effect. It is already known that the temperature minimum at the elastic-plastic transition can be used for the determination of the onset of yielding. Conceivable parameters for this have already been presented and investigated. Within this study factors influencing the specimen temperature during tensile loading and unloading are experimentally analyzed to improve the determination approach and the understanding of it. Furthermore, the robustness and repeatability of the measurement and evaluation procedures are analyzed. Therefore, cyclic tensile tests with the mild steel DC06 and the high strength steel CR590Y980T (DP1000) are performed with four PT1000 sensors applied on the specimen. The temperature behavior during elastic loading, elastic-plastic elongation and elastic unloading is separately evaluated. Different strain rates are investigated to better understand the strain-dependent heat development and its influence on the temperature-dependent evaluation. In this way, correlations between strain rate and thermal conduction due to prevailing temperature differences are found and their influence on the temperature-based determination of the onset of yielding is analyzed. Therefore, the yield stress at temperature minimum YS_Tmin as well as an additional yield stress at zero plastic strain YS₀ are evaluated for all experiment settings. In a comprehensive experimental study, the standard deviations are compared and thus conclusions can be drawn about the robustness of the determination methods.

Abstract: The high flux neutron diffractometer STRESSSPEC at FRM II, Garching Germany, offers a flexible instrument setup suitable for fast and surface residual strain measurements. Likewise bulk, local or gradient texture analyses are feasible. Here improvements of the hardware (detector, slits) of the instrument as well as developments on methods for residual stress analysis are presented. A new detector system developed inhouse was recently installed and successfully commissioned. Compared to the original delay line detector the new detector provides much higher resolution and allows event mode type measurements. Results of the commissioning measurements show a performance increase of nearly a factor of 2 compared to the former detector. Moreover the new analytical model, recently developed for surface spurious strain corrections, was successfully applied at a welded austenitic steel sample. Thus nondestructive measurements from the surface (200 μm) into the bulk (several millimeters) are possible without any extra time consuming experiments for spurious strains corrections.

Abstract: The accurate determination of strain during measurement using neutron diffraction depends on many factors. The statistical uncertainty of the diffraction data is not always the most important contributor to the total uncertainty in the measured strain. Other contributors, such as sample positioning, size and shape of the sampling (gauge) volume and the size and distribution of grains within the sampling volume, often play an important role as well. Grain size issues have been the least studied and their impact is often ignored even though the potential uncertainty contribution can be large. Certain methods such as oscillating the sample during measurement can help in reducing the magnitude of the grain size effect and hence also that of the related uncertainty contribution. A thorough characterization of uncertainties due to grain size effects however, in terms of absolute values that should be added to the statistical peak fitting uncertainties has not yet been implemented. This paper will present an improved method to characterize and estimate absolute uncertainty values due to grain size effects.

Abstract: In this study local texture of process vessels made of carbon steel cladded by protective layers of stainless steel by submerged arc welding (SAW) were investigated by neutron diffraction using the diffractometer STRESSSPEC at FRM 2 (Garching, Germany). Different samples were prepared: as welded and as welded plus relevant industrial heat treatment. Local texture measurements with a gauge volume of 3 x 3 x 2 mm³ of the three cladding layers (at depths of 2 mm, 5 mm and 7.5 mm) for each sample were determined. Texture results indicated that there exists an annealed cube component in all the studied samples. Based on the measured pole figures at each depth and sample, the calculated orientation distribution functions data were used to calculate the Young's modulus with respect to the main welding directions. The calculated local and bulk anisotropic Young’s modulus in depth is presented and discussed.

Abstract: With respect to residual stress analysis the inner gearing of an automotive sliding collar is a component with a challenging, complex geometry. The accessibility of the tooth root does not exist for conventional measuring approaches. However, the process steps like e.g. broaching and case hardening induce characteristic residual stress distributions, which must be known for the valuation of the mechanical integrity of the parts. For lab X-ray stress analysis approaches according to the sin2ψ-method [1] the ring like structure must be sectioned, which affects the process induced residual stress state. The tooth root is rather small, which further leads to shadowing effects during tilting of the sample. Standard mechanical approaches like incremental hole drilling can be excluded due to the narrow tooth root. Local neutron diffraction residual stress analysis in the tooth root by means of neutron through surface strain scanning at the STRESS-SPEC instrument at the research reactor FRM II, Garching (Germany) was successfully carried out for the inner gearing. A measuring and evaluation strategy is proposed, where special attention is paid to the compensation of the surface effect due to the incomplete immersion of the nominal gauge volume during through surface scanning and to the local variation of the D₀-value as a consequence of the case hardening process.

Abstract: For non destructive stress analysis of surface treated steel samples the application of laboratory X rays or high energy synchrotron radiation in reflection mode covers the region from some micrometers up to a depth of about 150 - 200 µm. To access depth regions deeper than 200 µm the incremental layer removal technique in combination with the repeated application of X‑ray stress analysis for the newly generated surfaces can be used. However, this procedure is destructive, laborious and furthermore, it has to be checked whether corrections have to be applied due to stress relaxation. By using neutron radiation penetration depths generally up to several millimetres can be achieved non destructively [1]. However neutron measurements are critical at the surface. When scanning a sample surface, aberration peak shifts caused by so called spurious strains arise due to the fact that the gauge volume defined by the primary and secondary optics is partially outside of the sample. These aberration peak shifts can be of the same order of magnitude as the peak shifts related to residual strains [2-6]. In this exemplary study it will be demonstrated that, by optimising the bending radius of a Si (400) monochromator, the spurious surface strains can be strongly reduced when compared to the values obtained with a traditional Ge (311) mosaic monochromator, even when the gauge volume is mainly out of the surface. The objective of the experiments is to find the optimal monochromator settings for the Si (400) monochromator at the STRESS-SPEC instrument at the research reactor FRM II, Munich, Germany. For the parametric studies a stress free steel sample of the fine grained construction steel, S690QL was used. The optimised conditions for the Si (400) monochromator that resulted from the systematic studies were applied to a shot peened plate of steel SAE 4140. The residual stress distribution is analysed by means of through surface strain scanning. The residual stress gradient obtained is in very good agreement with the well characterised residual stress depth profile obtained within a round robin test in the scope of the BRITE-EURAM-project ENSPED (European Network of Surface and Prestress Engineering and Design) [7]. The results indicated that surface residual stress profiles can be measured with neutrons up to 200 µm underneath the surface without time consuming and laborious surface effect corrections.

Abstract: The influence of the heat treatment on the residual stress fields of weld cladded samples is discussed in this paper. The samples were elaborated from carbon steel plates, cladded in one of the faces with stainless steel filler metals by submerged arc welding. After the cladding process some of the samples were submitted to heat treatments with different parameters: one at 620° C for a holding time of 1 hour and the other at 540° C for a period of ten hours. The in‑depth residual stress profiles were determined by neutron diffraction. The results shown that the sample treated to 620 °C, presented the highest residual stress relaxation. The corresponding heat treatment has the industrial benefit to be shorter than the other heat treatment.

Abstract: The determination of strain from neutron diffraction data is normally based upon the fit of a Gaussian function to a Bragg reflection. The error in the fit is assumed to be that based on ‘counting statistics’ and this error propagates through the analyses until the final stress evaluation. This relies on there being a big enough number of diffracting grains/crystallites within the gauge volume to ‘approximate’ to counting statistics. The number of grains however depends on the gauge volume size chosen and the average size of the grains (and hence diffracting grains) within the gauge volume and this should be taken into account. The aim of this work is to give an estimate of the uncertainty due to these ‘grain-size statistics’ due to grain size, gauge volume, FWHM of the Bragg reflection (for angular dispersive diffractometers), scattering angle (2), size of detector (and hence number of diffracting grains ‘seen’ on the detector), hkl multiplicity (m) and eventually texture.

Abstract: In response to the development of new materials and the application of materials and components in new technologies the direct measurement, calculation and evaluation of textures and residual stresses has gained worldwide significance in recent years. Non-destructive analysis for phase specific residual stresses and textures is only possible by means of diffraction methods. In order to cater for the development of these analytical techniques the new Materials Science Diffractometer STRESS-SPEC at FRM-II is designed to be equally applied to texture and residual stress analyses by virtue of its flexible configuration. The system compromises a highly flexible monochromator setup using three different monochromators: Ge (511), bent silicon (400) and pyrolitic graphite (PG). This range of monochromators and the possibility to vary the take-off angles from 2θM = 35º to 110º allows wavelength adjustment such that measurements can be performed around a scattering angle of 2θS ~ 90º. This is important in order to optimise neutron flux and resolution, especially for stress analysis on components, since the gauge volume element in that case is cubic and large vertical divergences due to focusing monochromators do not affect the spatial resolution. The instrument is now available for routine operation and here we will present details of recent experiments and instrument performance.