Materials Science Forum Vols. 768-769

Abstract: Energy dispersive synchrotron diffraction has been carried out on cold drawn pearlitic steel wires. In this paper the observed cementite peaks are analysed. For a broad range of true drawing strains sin²(Ψ) curves have been measured. The residual stress in the cementite is found to saturate after reaching a maximum at a strain of about 1.6. No indication of significant texture development in the cementite could be observed. An explanation is given in terms of possible physical mechanisms. Peak broadening was observed at the early stages of deformation.

Abstract: Abstract. There is growing interest in laser machining as an alternative to abrasive processes for creating cutting tool micro geometries. This technology is also suitable for creating micro geometries on cutting edges of superhard cutting tools. The pulsed nanosecond lasers, which are commonly used for this type of application, induce a high thermal load in the tool. This heat is believed to result in tensile residual stresses at the cutting edge surface, which are generally unfavorable for cutting tool performance because of the tendency to crack formation and propagation. Different levels of compressive residual stress exist after each step (sintering, grinding, shot peening, etching and PVD-coating). From investigations of commercial processes for manufacturing PVD-coated carbide cutting tools it is known that the final residual stress state of the carbide subsurface is a result of superposition of the stress states resulting from the individual process steps. In contrast to that, a laser machining process is expected to produce tensile residual stress due to the heat input. The present work describes the influence of a process chain alteration for PVD-coated carbide cutting tools by a laser machining process on the residual stress state in the finished tools.

Abstract: Aeronautic parts have generally complex structure and need high mechanical properties. Machining is an essential step to manufacture aluminium alloy aeronautical parts. To obtain parts complying with geometrical specifications, the machining process must be well understood and mastered. Indeed, many factors may induce geometrical deflections during the machining process. On large aeronautical parts, the main factor which can lead to non-complying part is the unexpected release of original residual stresses. In this work, a specific finite element solver has been developed to predict the distortion due to the redistribution of the original residual stresses during machining. Then, results obtained are compared with experimental tests to validate this approach.

Abstract: Stents are medical implants, which are applied to keep cavities in the human body open, e.g. blood vessels. Typically they consist of tube-like grids of suitable metal alloys. Typical dimensions depend on their applications: outer diameters in the mm-range and grid bar thickness in the 100 µm range. Before implantation, stents are compressed (crimped) to allow implantation in the human body. During implantation, stents are expanded, usually by balloon catheters. Crimping as well as expansion causes high strains and high stresses locally in the grid bars. These strains and stresses are important design criteria of stents. Usually, they are calculated numerically by Finite Element Analysis (FEA) [1,2]. The XRD-sin²ψ-technique is applied for in-situ-determination of stress conditions during crimping and expansion of stents of the CoCr-alloy L-605. This provides a realistic characterization of the near-surface stress state and an evaluation of the numerical FEA results. XRD-results show an increasing compressive load stress in circumferential direction with increasing stent expansion. These findings correlate with the numerical FEA results. Further residual stresses after removing the expansion device have been measured.

Abstract: Thermal influences, introduced intentionally or unintentionally do have significant effects on surfaces of steel components. Materials properties are reduced by annealing effects or even re-hardening zones can occur. Grinding, one of the most important technological processes for preci-sion manufacturing of hardened steel components, is an important source of thermal influences to steel surfaces. In pronounced cases, these influences are referred to as grinding burn. They are known as possible reasons for gray stains as well as development of cracks and pittings on heavy-duty gears and on roller bearings. The basic effect of thermal influences on the material is a change of the macro- and micro-residual stress states. Therefore, the knowledge of these residual stress states is of fundamental importance. The paper treats the mechanisms of grinding which can lead to thermal influences. Some characteristic appearances of grinding burn are shown and characterized by X-ray macro- and micro residual stress determinations. It is shown that defined laser treatments can be used to create reproducible thermal influences similar to grinding burn. Their effects are also characterized by X-ray residual stress measurements. The sensitivities of X-ray and metallographical investigations are compared. Defined laser traces are proposed as calibration samples for magnetic and eddy current measurements which allow to determine threshold values for the actual apparatus and measuring problem.

Abstract: In this paper the microstructural and residual-stress analysis of an induction hardened plate of medium carbon steel is described. The stress gradient was determined using laboratory X-ray diffraction (IWT, Bremen, Germany) and neutron strain scanning (ILL, Grenoble, France). Due to slight variations of chemical composition in the depth, matchstick like (cross section 2×2mm²) d₀-reference samples were prepared from a similarly treated sample. The d₀ shift induced by variation of chemical composition was measured by neutron and by X-ray diffraction along the strain free direction (sin²ψ*) and used for the evaluation of the neutron stress calculation. The d₀ distribution obtained from the neutron measurement did not appear reliable while the method using X-ray diffraction seems to be an efficient and reliable method to determine d₀ profiles in small samples. The evaluation of neutron measurements was then done using the X-ray diffraction d₀ distribution. High compressive residual stresses were measured in the hardened layer followed by high tensile residual stresses in the core. A comparison of the neutron measurements with X-ray diffraction (XRD) depth profiles obtained after successive layer removal showed that both methods give similar results. However, these investigations opened the question about the direct comparison of the residual stresses obtained by neutron and XRD. Indeed, a correction of the neutron data regarding the residual stresses in thickness direction might be necessary as these are released in the case of X-ray diffraction measurements after layer removal.

Abstract: Residual strains near the sprues of ingots with different contents of Zn (6 wt. % and 9 wt. %) were measured using neutron diffraction. The results showed that the increase of Zn content decreases the residual stress in the hot sprue region. These results are good in agreement with that obtained by the measurement of hot tearing susceptibility.

Abstract: A series of samples from four automotive materials - AKDQ, HSLA50, DP600, and AA6022-T43 - were deformed in a channel draw processes with different levels of draw bead penetration. As a result, varying magnitudes of deformations in plane strain mode and residual stresses were obtained. Through-thickness stress profiles were obtained non-destructively using a novel, high resolution X-ray diffraction technique.

Abstract: Biaxial yield behavior is determined in-situ through X-ray lattice strain measurements. The distributions of d-spacings in different sample directions is affected both by the changes in diffraction elastic constants (DEC) from evolving texture and by the intergranular (IG) strains. Model predictions were found to be lacking, thus, a hybrid approach was developed based on measurements of DEC and IG strains at selected biaxial deformations. In order to convert measured lattice strains to stress for any given biaxial plastic strain a theoretical approximation was fitted to the experimental data, thus allowing the estimation of the evolution of DEC and IG strains with plastic deformation.

Abstract: The in-plane residual stresses in laser cladded specimens, made of 12-nickel precipitation hardening maraging hot-working tool steel 1.2799 (SIST EN 10027-2) are analyzed using the hole drilling method. The CO2 laser was used to deposit the alloy NiCoMo-1 with significantly higher content of nickel and cobalt with austenitic microstructure at room temperature. The Nd:YAG laser was used to deposit the maraging alloy designated NiCoMo-2, with similar chemical composition as the base material. The comparison of residual stress field showed the sign and the magnitude of residual stresses depends on the chemical composition of the clad being deposited. The high tensile residual stresses were found in NiCoMo-1 layers and favorable compressive residual stresses were found in NiCoMo-2 layers. The metallurgical aspects of residual stress generation are discussed.