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2theta
156.6 156.6
(>0) <0 = -21.7ksi
156.4 156.4 (<0)
156.2 156.2
156 156
0 0.1 0.2 0.3 0.4
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
2
Sin ( ) 2
Sin ( )
Correct Incorrect
Automated Stress Mapping
Multiple Map Analysis
As welded Shot peened
Surface Bending - Stress Mapping
Compressive stresses shown in blue
Tensile stresses shown in red
Stress gradients must be mapped
The Equipment
The instrument must suit the job
High power x-ray tube
system for high speed
MG2000 measurements.
To measure inside a 90
mm bore.
MG15P
Purpose:
Determine the residual stresses as a
result of cold expanding the i.d. of a
bolt hole.
Optimize compressive stress layer by
increasing ball diameter.
Ball Expanded Bolt Hole
Ball Expanded Hole - I.D.
20
10
0
Residual Stress (ksi)
-10
-20
1.7 increase
4.8 increase
-50
0.0000 0.0050 0.0100 0.0150 0.0200
Depth (inch)
Ball Expanded Bolt Hole
Conclusions:
Stress relief cycle results in low residual
stresses.
0.8 increase has minimal effect.
1.7 increase introduces significant
compressive layer.
4.8 increase introduces deepest compressive
layer and tensile stresses at the surface.
Crankshaft - Rolled fillet radius!
Purpose:
Determine the RS as a result of rolling
journal fillet undercut to inhibit the initiation
and propagation of fatigue cracks.
Characterize RS gradients as a function of
depth.
Measure RS at different angles around the
circumference to compare rolling pressure
variations.
Crankshaft - Rolled fillet radius!
Re sid u al S tres s vs. Dept h
in R o lled C ra n ks h aft F illets
0
Lo w Rolli ng P re ssu re
-4 0
-6 0
-8 0
-10 0
0. 00 0 0. 01 0 0. 02 0 0. 03 0 0. 04 0 0. 05 0 0. 06 0
D epth (inche s)
Crankshaft - Rolled fillet radius!
Conclusions:
Rolling can introduce a very deep
compressive residual stress layer.
The magnitude of RS layer varies with rolling
pressure.
The SCF in a concentration geometry can be
determined experimentally
Crankshaft - Journal!
Purpose:
Measure RS as a result of final grind to
detect grinder burn.
Characterize RS gradient as a function of
depth.
Measure RS at different angles around the
circumference to find variations.
Optimize grinding parameters
Crankshaft - Journal!
Grou n d C ran ksh a ft J o urn als
2 50
P in #1
P in #2
2 00
P in #3
P in #4
1 50 Ma in #2
Ma in #3
Ma in #4
Axia l R e sidu a l S tre ss (k si)
1 00
50
-50
-1 00
-1 50
-2 00
-2 50
0.0 00 0.0 20 0.0 40 0.0 60 0.0 80 0.1 00
D ep th (in .)
Crankshaft - Journal!
Conclusions:
Grinding can introduce very high tensile RS
near the surface (grinder burn).
The RS layer varies with grinding parameters
(wheel type, feed, speed, coolant etc)
Weldments
Purpose:
Determine residual stresses
introduced by the welding process.
Evaluate thermal and vibratory stress
relief
Compare Effects of TSR and VSR
HR 1020 Residual Stress vs Distance from Weld Toe
50.0
40.0
Conclusions:
The welding process introduced
significant tensile residual stress in the
weld HAZ.
The thermal stress relief cycle was
successful in relaxing tensile residual
stresses due to welding.
The vibratory stress relief did nothing.
Gears - Effects of Peening!
Purpose:
Determine the RS as a result processing
prior to peening.
Characterize RS gradients as a function of
depth.
Compare the RS due to different levels of
peening and prior processing.
Gears - Effects of Peening!
-20
-40
-60
Stress (ksi)
-80
-100
-120
-180
0.0000 0.0050 0.0100 0.0150 0.0200
Depth (in.)
Gears - Effects of Peening!
Conclusions:
Peening can introduce a deep compressive
residual stress layer.
The magnitude of RS layer varies with
peening parameters.
The effect of peening can be compared to the
baseline.
Summary - What can I do with XRD?
XRD can be used to measure residual
stress in automotive components
Verify the root cause of failures
Characterize corrective actions applied
Enhance FEM designs
Incorporate mean stress in fatigue
predictions
Incorporate RS in fracture mechanics
Develop optimum processing
Implement quality assurance strategy