Skip to main content
SpringerLink
Log in

A new contour method for rapid evaluation of the cross-sectional residual stress distribution in complex geometries using a 3D scanner

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

This paper presents a new method for contour measurements using a 3D scanner to determine cross-sectional residual stresses in structural components with complex configurations. The proposed method was applied to evaluate the axial residual stress distribution in a dissimilar pipe weld and the obtained results were compared with those obtained using a benchmarked contour measurement machine (CMM) equipped with a confocal laser probe for verification. It reveals a quantitative agreement between the two methods in terms of both the measured contours and the calculated residual stresses. Most importantly, this method allows a significantly reduced measurement time by ≈99 % (≈20 min, with an effective measurement speed of ≈0.2 sec/mm2), compared to the benchmarked method (≈48 hr, with an effective measurement speed of ≈28.7 sec/mm2). Based on stress uncertainty analysis, this method guarantees a longer range of stable fits due to fewer noisy data points than the benchmarked method.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. P. Withers, Residual stress and its role in failure, Reports on Progress in Physics, 70 (12) (2007) 2211–2264.

    Article  Google Scholar 

  2. U. Zerbst, R. Ainsworth, H. T. Beier, H. Pisarski, Z. Zhang, K. Nikbin, T. Nitschke-Pagel, S. Münstermann, P. Kucharczyk and D. Klingbeil, Review on fracture and crack propagation in weldments - A fracture mechanics perspective, Engineering Fracture Mechanics, 132 (2014) 200–276.

    Article  Google Scholar 

  3. W. Zhang, W. Jiang, X. Zhao and S.-T. Tu, Fatigue life of a dissimilar welded joint considering the weld residual stress: Experimental and finite element simulation, International Journal of Fatigue, 109 (2018) 182–190.

    Article  Google Scholar 

  4. G. S. Schajer (ed.), Practical Residual Stress Measurement Methods, John Wiley & Sons, Singapore (2013).

    Book  Google Scholar 

  5. W. Cheng and I. Finnie, Residual stress measurement and the slitting method, Springer Science & Business Media, Boston, MA, USA (2007).

    Google Scholar 

  6. W. Woo, G. An, E. Kingston, A. DeWald, D. Smith and M. Hill, Through-thickness distributions of residual stresses in two extreme heat-input thick welds: A neutron diffraction, contour method and deep hole drilling study, Acta Materialia, 61 (10) (2013) 3564–3574.

    Article  Google Scholar 

  7. H. Wang, W. Woo, D. Kim, V. Em, I. Karpov, G. An and S. Lee, Effect of tailored martensitic transformation in a thick weld: Residual stresses mitigation, heterogeneous microstructure, and mechanical properties, Materials Characterization, 144 (2018) 345–355.

    Article  Google Scholar 

  8. H. Wang, W. Woo, D. Kim, V. Em and S. Y. Lee, Effect of chemical dilution and the number of weld layers on residual stresses in a multi-pass low-transformation-temperature weld, Materials & Design, 160 (2018) 384–394.

    Article  Google Scholar 

  9. W. Woo, D.-K. Kim, E. J. Kingston, V. Luzin, F. Salvemini and M. R. Hill, Effect of interlayers and scanning strategies on through-thickness residual stress distributions in additive manufactured ferritic-austenitic steel structure, Materials Science and Engineering: A, 744 (2019) 618–629.

    Article  Google Scholar 

  10. W. Jiang, Y. Luo, J. Li and W. Woo, Residual stress distribution in a dissimilar weld joint by experimental and simulation study, Journal of Pressure Vessel Technology, 139 (1) (2017) 011402.

    Article  Google Scholar 

  11. H. Wang, W. Woo, S. Y. Lee, G. An and D. Kim, Correlation of localized residual stresses with ductile fracture toughness using in situ neutron diffraction and finite element modelling, International Journal of Mechanical Sciences, 160 (2019) 332–342.

    Article  Google Scholar 

  12. M. B. Prime, Cross-sectional mapping of residual stresses by measuring the surface contour after a cut, Journal of Engineering Materials and Technology, 123 (2) (2001) 162–168.

    Article  Google Scholar 

  13. M. B. Prime, R. J. Sebring, J. M. Edwards, D. J. Hughes and P. J. Webster, Laser surface-contouring and spline data-smoothing for residual stress measurement, Experimental Mechanics, 44 (2) (2004) 176–184.

    Article  Google Scholar 

  14. J. Kelleher, M. Prime, D. Buttle, P. Mummery, P. Webster, J. Shackleton and P. J. Wthers, The measurement of residual stress in railway rails by diffraction and other methods, Journal of Neutron Research, 11 (4) (2003) 187–193.

    Article  Google Scholar 

  15. M. R. Hill and J. E. VanDalen, Evaluation of residual stress corrections to fracture toughness values, Journal of ASTM In-ternational, 5 (2008) 1–11.

    Google Scholar 

  16. W. Woo, H. Choo, M. Prime, Z. Feng and B. Clausen, Micro-structure, texture and residual stress in a friction-stir-processed AZ31B magnesium alloy, Acta Materialia, 56 (8) (2008) 1701–1711.

    Article  Google Scholar 

  17. H. Bueckner, The propagation of cracks and the energy of elastic deformation, Transactions of the ASME, 80 (1958) 1225–1230.

    Google Scholar 

  18. F. Hosseinzadeh, J. Kowal and P. J. Bouchard, Towards good practice guidelines for the contour method of residual stress measurement, The Journal of Engineering, 8 (2014) 453–468.

    Article  Google Scholar 

  19. Y. Wan, W. Jiang, J. Li, G. Sun, D.-K. Kim, W. Woo and S. Tung, Weld residual stresses in a thick plate considering back chipping: Neutron diffraction, contour method and finite element simulation study, Materials Science and Engineering A, 699 (2017) 62–70.

    Article  Google Scholar 

  20. J. Xia and H. Jin, Numerical analysis for controlling residual stresses in welding design of dissimilar materials girth joints, International Journal of Precision Engineering and Manufacturing, 19(1) (2018) 57–66.

    Article  Google Scholar 

  21. GOM, https://www.gom.com/3d-software/gom-inspect.html.

  22. T. G. Hicks, W. R. Mabe, J. R. Miller and J. V. Mullen, Residual stress evaluation of small diameter stainless steel piping by experimental measurements and finite element analysis, Prof, of the ASME Pressure Vessels and Piping Conference, Anaheim, California, USA (2014) V06BT06A077.

    Google Scholar 

  23. H. W. Lee, K.-J. Yu, T. M. Tien, I.-Y. Moon, Y.-S. Oh, S.-H. Kang and D.-K. Kim, Effect of quenching tempering-post weld heat treatment on microstructure and mechanical properties of laser-arc hybrid welded boron steel, Materials, 12 (2019) 2862.

    Article  Google Scholar 

  24. D.-K. Kim, W. W. Park, H. W. Lee, S. H. Kang and Y. T. Im, Adaptive characterization of recrystallization kinetics in IF steel by electron backscatter diffraction, Journal of Microscopy, 252 (2013) 204–216.

    Article  Google Scholar 

  25. D. D. Gu, W. Meiners, K. Wssenbach and R. Poprawe, Laser additive manufacturing of metallic components: Materials, processes and mechanisms, International Materials Reviews, 57 (2012) 133–164.

    Article  Google Scholar 

  26. T. DebRoy, H. L. Wei, J. S. Zuback, T. Mukherjee, J. W. Elmer, J. O. Milewski, A. M. Beese, A. Wlson-Heid, A. De and W. Zhang, Additive manufacturing of metallic components -Process, structure and properties, Acta Materialia, 92 (2018) 112–224.

    Google Scholar 

  27. H. W. Lee, K.-H. Jung, S.-K. Hwang, S.-H. Kang and D.-K. Kim, Microstructure and mechanical anisotropy of CoCrW alloy processed by selective laser melting, Materials Science and Engineering A, 749 (2019) 65–73.

    Article  Google Scholar 

  28. D.-K. Kim, W. Woo, E.-Y. Kim and S. H. Choi, Microstructure and mechanical characteristics of multi-layered material composed of 316L stainless steel and ferritic steel produced by direct energy deposition, Journal of Alloys and Compounds, 11A (2019)896-907.

  29. D.-K. Kim, J. H. Hwang, E. Y. Kim, Y. U. Huh, W. Woo and S. H. Choi, Evaluation of stress-strain relationship of constituent phases in AISMOMg alloy produced by selective laser melting using in-situ neutron diffraction and crystal plasticity FEM, Journal of Alloys and Compounds, 714 (2017) 687–697.

    Article  Google Scholar 

  30. D.-K. Kim, W. Woo, J. H. Hwang, K. An and S. H. Choi, Stress partitioning behavior of an AISMOMg alloy produced by selective laser melting during tensile deformation using in situ neutron diffraction, Journal of Alloys and Compounds, 686 (2016) 281–286.

    Article  Google Scholar 

  31. J. Ning, D. E. Sievers, H. Garmestani and S. Y. Liang, Analytical modeling of in-process temperature in powder bed additive manufacturing considering laser power absorption, latent heat, scanning strategy, and powder packing, Materialia, 12 (2019) 808: 1–16.

    Article  Google Scholar 

  32. J. Ning, D. E. Sievers, H. Garmestani and S. Y. Liang, Analytical modeling of transient temperature in powder feed metal additive manufacturing during heating and cooling stages, Applied Physics A Materials Science & Processing, 125 (2019) 496.

    Article  Google Scholar 

  33. J. Ning, E. Mirkoohi, Y. Dong, D. E. Sievers, H. Garmestani and S. Y. Liang, Analytical modeling of 3D temperature distribution in selective laser melting of Ti-6AI-4V considering part boundary conditions, Journal of Manufacturing Processes, 44 (2019) 319–326

    Article  Google Scholar 

  34. T. Mukherjee, W. Zhang and T. DebRoy, An improved prediction of residual stresses and distortion in additive manufacturing, Computational Materials Science, 126 (2017) 360–372.

    Article  Google Scholar 

  35. L. Cheng, X. Liang, J. Bai, Q. Chen, J. Lemon and A. To, On utilizing topology optimization to design support structure to prevent residual stress induced build failure in laser powder bed metal additive manufacturing, Additive Manufacturing, 27 (2019) 290–304.

    Article  Google Scholar 

  36. J. Ning, V. Nguyen, Y. Huang, K. T. Hartwig and S. Y. Liang, Inverse determination of Johnson-Cook model constants of ultra-fine-grained titanium based on chip formation model and iterative gradient search, The International Journal of Advanced Manufacturing Technology, 99 (2018) 1131–1140.

    Article  Google Scholar 

Download references

Acknowledgments

This work was supported by the Research Fund of the University of Ulsan.

Author information

Authors and Affiliations

  1. Dept. of Virtual Materials Processing, Korea Institute of Materials Science, Changwon, 51508, Korea

    Huai Wang

  2. School of Mechanical Engineering, University of Ulsan, Ulsan, 44610, Korea

    Dong-Kyu Kim

  3. Neutron Science Center, Korea Atomic Energy Research Institute, Daejeon, 34057, Korea

    Wanchuck Woo

  4. Dept. of Printed Electronics Engineering, Sunchon National University, Sunchon, 57922, Korea

    Shi-Hoon Choi

  5. Dept. of Materials Science and Engineering, Chungnam National University, Daejeon, 34134, Korea

    Soo Yeol Lee

  6. Extreme Fabrication Technology Group, Korea Institute of Industrial Technology, Daegu, Korea

    Sun-Kwang Hwang

Authors
  1. Huai Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dong-Kyu Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wanchuck Woo
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shi-Hoon Choi
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Soo Yeol Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Sun-Kwang Hwang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dong-Kyu Kim.

Additional information

Recommended by Editor Chongdu Cho

Huai Wang is a Postdoctoral Researcher in the Dept. of Virtual Materials Processing, Korea Institute of Materials Science, Changwon, Korea. He got his doctoral degree in Material Science and Engineering from Chungnam National University in Korea. His research interests include determination of residual stress with both destructive and non-destructive methods and by finite element modelling.

Dong-Kyu Kim is an Assistant Professor in the School of Mechanical Engineering, University of Ulsan, Ulsan, Korea. His research interests include computational materials modeling and it application to the manufacturing processes and residual stress evaluation.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, H., Kim, DK., Woo, W. et al. A new contour method for rapid evaluation of the cross-sectional residual stress distribution in complex geometries using a 3D scanner. J Mech Sci Technol 34, 1989–1996 (2020). https://doi.org/10.1007/s12206-020-0420-0

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-020-0420-0

Keywords

Search

Navigation