Residual Stress Analysis: An Essential Tool for Pelton Runner Lifespan Evaluation

Abstract:

The structural integrity of Pelton runners, crucial in hydroelectric power generation, is severely compromised by suboptimal repair practices, leading to premature failures and significant operational losses. This study presents a comprehensive analysis of five Latin American case studies (Colombia, Perú and Guatemala), revealing a direct correlation between uncontrolled residual stress and accelerated component degradation. This study demonstrates the effectiveness of integrating XRD with other Non-Destructive Testing (NDT) techniques, enabling the development of predictive models for crack propagation and the optimization of repair protocols. In addition, the results provide evidence that Pelton wheels repair transcends conventional welding, necessitating a profound understanding of residual stress distribution. Precise XRD-driven residual stress determination, pre-and post-intervention, is pivotal for implementing corrective thermal treatments and extending component lifespan. This study demonstrates that integrating XRD into maintenance protocols for Pelton runners constitutes a paradigm shift in structural integrity management. This innovative approach, by enabling precise residual stress analysis, minimizes catastrophic failures and maximizes operational efficiency within hydroelectric power generation. The findings validate the hypothesis that XRD-driven maintenance strategies significantly enhance component longevity and reliability, thereby revolutionizing industry standards.

• Periodical: Key Engineering Materials (Volume 1033)
• Pages: 49-58
• DOI: https://doi.org/10.4028/p-Q3tgv2
• Online since: November 2025
• Authors: Camilo Seifert, Sebastian Acuña, Daniel Hincapie, Andres Felipe Duque, Alejandro Morales-Ortiz*
• Keywords: Pelton Runner, Premature Failure, Residual Stress, X-Ray Diffraction

References

[1] Prevey, P. S. "A comparison of residual stress measurement methods using X-ray diffraction." Experimental Mechanics, 1993, 33(1), 14-24.

[2] M. Yavuz Peter McIntyre, I. L. Karaman Dennis O, and O. Anderoglu, "Residual Stress Measurement Using X-Ray Diffraction," Texas A&M Univ., no. December, p.1–64, 2004.

[3] C. O. Ruud, "Residual Stress Measurements," Mechanical Testing and Evaluation, vol. 8. ASM International, p.0, 01-Jan-2000.

[4] Meguid, S. A., & Shagal, G. "The role of residual stresses in fatigue crack growth." International Journal of Fatigue, 2002, 24(1), 35-42.

[5] W. Z. Zhuang and G. R. Halford, "Investigation of residual stress relaxation under cyclic load," Int. J. Fatigue, 2001.

[6] Z. Wang and B. Gong, "Handbook of Residual Stress and Deformation of Steel," in Handbook of Residual Stress and Deformation of Steel, 2002, p.143–154.

[7] R. Guinebretiere, X-ray diffraction by polycrystalline materials. ISTE, 2007.

[8] G. E. Totten, M. A. H. Howes, and T. Inoue, Handbook of residual stress and deformation of steel. ASM International, 2002.

[9] Cai, Y., et al. "A review of residual stress measurement techniques." Journal of Materials Science & Technology, 2016, 32(6), 582-596.

[10] Withers, P. J., & Bhadeshia, H. K. D. H. "Residual stresses part 2—modeling." Materials Science and Technology, 2001, 17(4), 366-375.

[11] P. J. Withers and H. K. D. H. Bhadeshia, "Residual stress. Part 1 – Measurement techniques," Mater. Sci. Technol., vol. 17, no. 4, p.355–365, Apr. 2001.

[12] O. Anderoglu, "Residual Stress Measurement Using X-Ray Diffraction," Texas A&M Univ., 2004.

[13] C. O. Ruud, "Residual Stress Measurements," Mechanical Testing and Evaluation, vol. 8. ASM International, p.0, 01-Jan-2000.

[14] A. K. Chatterjee, "8 - X-Ray Diffraction," V. S. Ramachandran and J. J. B. T.-H. of A. T. in C. S. and T. Beaudoin, Eds. Norwich, NY: William Andrew Publishing, 2001, p.275–332.

[15] Meguid, S. A. "Mechanics of welding residual stresses." Journal of Materials Processing Technology, 1995, 48(1-4), 1-12

[16] N. H, A. Hirose, and S. Sogabe, "13 Cr - 3.5 Ni Martensitic Stainless Steel Casting For Hydraulic Turbine Runners", 1986.

[17] Meguid, S. A. "Mechanics of welding residual stresses." Journal of Materials Processing Technology, 1995, 48(1-4), 1-12

[18] Hauk, V. M. "Evaluation of residual stresses by X-rays and neutrons." Materials Science and Engineering, 1997, 222(1), 1-15.

[19] W. J. Sames, F. A. List, S. Pannala, R. R. Dehoff, and S. S. Babu, "The metallurgy and processing science of metal additive manufacturing," International Materials Reviews. 2016.

DOI: 10.1080/09506608.2015.1116649

[20] V. Hauk, "Structural and residual stress analysis by nondestructive methods," Inst. Mater. London, UK, 1997.

[21] R. Kohli, "Chapter 3 - Methods for Monitoring and Measuring Cleanliness of Surfaces," R. Kohli and K. L. B. T.-D. in S. C. and C. Mittal, Eds. Oxford: William Andrew Publishing, 2012, p.107–178.

DOI: 10.1016/b978-1-4377-7883-0.00003-1

[22] D. Delbergue, D. Texier, P. Bocher, R. Stresses, and X. E. Constant, "Comparison of Two X-Ray Residual Stress Measurement Methods: Sin2 ψ and Cos α, Through the Determination of a Martensitic Steel X-Ray Elastic Constant," Residual Stress. 2016, vol. 2, p.55–60, 2016.

DOI: 10.21741/9781945291173-10