Analysis of Residual Stress

and its evaluation

Dr. S. Suresh
 RESIDUAL STRESS

Stress that exists after removal of

external load
It is self equilibrating in nature

It is elastic in nature

Its consequences are realized only in

service
 RESIDUAL STRESS

Is Caused
by
Non uniform flow
Localised plastic deformation
Differential expansion
Volume expansion
Shape change deformation
 Assumption Reality

Material is Material is
Homogeneous and Heterogeneous
isotropic and an-isotropic

It is free from Micro level

Defects defects always
exist

It is Stress Free It always carries

residual stress
 STRESS CORROSION CRACKS IN Al-Zn-Mg
ALLOY (7075-T6511)

Stress in MPa
Time to fracture
Dia 116 mm Extruded Bar
Hydrogen Induced Cracking
 EFFECT OF RESIDUAL STRESS ON
BUCKLING STRENGTH OF COLUMNS
AS-WELDED
CRITICAL STRESS / YIELD STRESS

STRESS
RELIEVED

SLENDERNESS RATIO L/r

INFLUENCE OF RESIDUAL STRESS ON FATIGUE

STRESS
RELIEVED JOINT
STRESS RANGE

AS WELDED
JOINT

NUMBER OF CYCLES
ANGULAR DISTORTION

D
 UP HILL MILLING

ROLLING

DOWN HILL MILLING

GRINDING

WELDING HARDENING

MANUFACTURING PROCESSES THAT

PRODUCE RESIDUAL STRESS
LONGITUDINAL RESIDUAL STRESS DUE TO
ROLLING

COMPRESSION 0 TENSION

0
LONGITUDINAL RESIDUAL STRESS IN WIRE DRAWING
TENSION

TENSION
0 0
COMPRESSION

COMPRESSION
0 0

WITH SHALLOW WITH DEEP

PENETRATION PENETRATION
 Residual stress distribution

Temp distbn Res. Stress distbn

 Residual stress distribution

Temp distbn Res. Stress distbn

 Residual stress distribution

Temp distbn Res. Stress distbn

 Residual stress distribution

Temp distbn Res. Stress distbn

Residual stress Residual stress distribution
RESIDUAL STRESS IN WELDING

N
IO
NS
TE
ON
SI
ES
PR
M
CO
 Typical patterns of Residual Stress
distributions observed in different steels

Carbon Steels Low alloy steels High alloy

steels
 Application of
Strain gauge technique to
Measure Residual stress

WRI
HOLE DRILLING ROSETTE STRAIN GAUGE FOR RESIDUAL
STRESS MEASUREMENT

c
45

0 d a

b
90
Configuration of rectangular Rosette strain Gauge
c
b

Dia 1.6 mm
hole

a
Orientation of the strain gauge with respect to welded Plate

c
45

d a
0

b
90
Hole drilling gauge installed on the austenitic
stainless steel weld zone
Blind Hole drilling Jig
used for Residual
Stress measurement
used in the
study
 Drilling Jig used
For blind hole
Drilling

Special Hole
drilling gauge
Incremental Drilling
Through the Jig for
Strain relaxation

Multi-channel
Digital strain meter
 Incremental Blind Hole drilling

d
Z

100

80
% Strain Relaxed

60

40

20
Z/d ratio
0 0.2 0.4 0.6 0.8 1.0
View of the drilled
Hole & the
Gauge after hole
Drilling

1.6 mm dia hole is

Drilled to a depth of 1.9 mm
In small incremental
depths
 Applications Railway Bogie frame

Top Flange
11 7 5 10
Diaphragm
Plate
1 2

8 4 3 6 9

20 mm
 Alignment of the
drilling jig
With the center
Of the strain gauge
Wiring of the
Strain gauge
With the
instrument
Strain gauge installation
in bogie frame and setting
of the drilling jig
Incremental
Drilling with
High speed
Turbine drive

WRI
 Welded High
Speed Railway
Bogie frame

WRI
Multi-channel digital
Strain Meter
 Residual stress in
as-welded condition

L1 L2 L3 L4 L5 L6 L7 L8 L9
n
io
at
c
Lo

Stress
MPa -57 -43 132 23 3 -134 -66 -65 -85

WRI
Application of over stressing technique in X-60
steel Pipe to minimize residual stress
Residual stress measurement by hole
Drilling method in X-60 steel Pipe
Blind hole drilling using air turbine drive to evaluate residual
stress in fusion welded line pipe
View of the drilled hole after blind hole drilling
Residual stress evaluation
 Application of
X-Ray Diffraction technique to
Measure Residual stress
PRINCIPLE OF X-RAY DIFFRACTION


 
d
d

n  = 2 d. SIN 
 REPRESENTATION OF MACRO & MICRO STRESSES

RS III
TENSILE STRESS

RS III
RS II

RS II RS I
COMPR.
STRESS
 REPRESENTATION OF MACRO & MICRO STRESSES

RS III
TENSILE STRESS

RS III
RS II

RS II RS I
COMPR.
STRESS
 EFFECT OF STRESS ON LATTICE SPACING

Normal to diffracting
Plane Normal to diffracting
Plane
Diffracted
Incident Beam Beam Diffracted
Incident Beam
Beam
o o
do
 
d

UNDEFORMED STATE DEFORMED STATE

do Lattice spacing under d Lattice spacing under

stress free state stressed state
 EFFECT OF MICRO & MICRO STRESS

INTENSITY
d

DEFORMED
STATE

Peak Shift due to Macro

Stress DIFFRACTION ANGLE 2
CRYSTALLINE ORIENTATION SUITABILITY
FOR DIFFRACTION
NORMAL TO NORMAL TO
DIFFRACTING PLANE DIFFRACTING PLANE

Diffracted beam

1
1 =25° 2 =45° 2
X-Ray Stress Analyzer

Control unit Goniometer

 Phi axis
rotation

X-Ray
Solid State
collimator
Detectors

X-ray Goniometer
  Residual Stress Measurement Parameters
Parameters Ferritic (BCC) Austenitic (FCC)

Radiation Cr K Cr K

Diffracting Plane (211) (300)

Exposure time 10 sec 10 sec

No of Exposures 14(+-7 & --7) 14(+-7 & --7)

No of Phi angles () 0, 45, 90 0, 45, 90

X-ay Voltage & 30 kV, 6,8 mA 30 kV, 6,8 mA

current
2 angle 156.40 140
Residual Stress Evaluation in
High Strength al. alloy tank
Residual Stress Evaluation in
High Strength al. alloy tank
METHODS TO INDUCE COMPRESSIVE STRESS

MECHANICAL THERMAL

SHOT PEENING SPOT HEATING

CONTACT ROLLING

NEEDLE PIN PEENING

HAMMER PEENING

WRI
 Gun

Base
Plate COMPRESSOR

NEEDLES

NEEDLE PIN
PEENING OF FULL
PENETRATION
TEE-SECTION
JOINTS
WRI
RESIDUAL
STRESS
EVALUATION

DIGITAL STRAIN
MILLING METER
GUIDE

Strain Gauge

WRI
 Effect of dressing of
weld toe on fatigue strength

Material - IS 2062 Process - FCAW

Joint - Fillet Stress range - 16 kg/mm2

Method Fatigue life Improvement

As welded 0.433 x 105 -

Toe Grinding 0.540 x 105 28 %

TIG Dressing 0.833 x 105 92 %

Effect of Needle pin peening
Material - St 335, Peened with
3 mm  HSS needles for 5 min

Maximum Stress in kg/mm2

Region As - welded Peened

Pipe + 2.64 - 28.90

Toe + 46.14 - 23.61

NEEDLE PIN PEENING OF SHAFT

FAN SHAFT MOCK UP

PIPE - SA 335,  605 mm
& FLANGE St 37 STEEL

WRI
 Residual Stress
Evaluation in
Mock Up Fan shaft
After Needle
Pin Peening
X-Ray
Stress Analyzer
used in the study
Thank You