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Residual Stress Measurements

in Automotive Components via


X-Ray Diffraction!
F. Cuccia
Proto Mfg. Inc. Taylor, MI USA
www.protoxrd.com
Notice
Please note some of the designs, techniques and
applications shown in this presentation are subject to
copyright, patents granted or pending.

Data is used with the permission of the respective


owner(s) and may not be reproduced without permission.
Introduction to XRD
How X-ray Diffraction works
Soft x-rays
constructively interfere
with the crystals in the
material

The diffraction cone


angle varies with
change in d to strain
as per Braggs Law:
n=2d sin

Elasticity - Hookes Law
Elasticity
Hookes law (1D):
= E
E: Youngs modulus
11 = E 11
22 33
= = , 22 = 33 = 11
11 11 E
The loading is reversible

Hookes law (3D) :


1 + Stress Strain
ij = ij ij kk
E E curve
dij=0 if i j, dij=1 if i= j
Technique Requirements
Material must be crystalline or poly-crystalline.
Requires Line of Sight access to
measurement surface.
Parts can be typically measured as is, heavy
combustion byproducts should be alkaline
cleaned. No mechanical cleaning techniques
should be applied as they may alter the residual
stress.
Requires competent operator, technician level
and above. (Proto offers training programs)
Total Stress = Residual + Applied
Validation: Standards &
Guidelines

SAE HS784 RS measurement


ASTM E2860 RS measurement
ASTM E915 RS Instrument Alignment
ASTM E1426 4 pt bend to determine XEC
ASM Handbook Vol.11 General guidelines
5 Steps to Data Confidence

1. Alignment of XRD instrument ASTM E915.


2. X-ray elastic constant determination ASTM E1426.
3. Surface condition evaluation.
4. Collection parameter selection (optimization).
5. Repeatability and reproducibility determination.
In the presence of shear stress the
elliptical method must be used
-Splitting on ground steel, Elliptical method -Splitting on ground steel,
Linear fits for >0 and <0
157.2
157.2

>0 = -52.7 ksi 157


157 = -13.6 ksi
<0
>0 >0 = -75.7ksi
156.8 156.8
<0
2theta ()

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.

Phi rotation for measuring


residual stress in multiple
MGR40P directions without
rotating part.

To measure inside a 90
mm bore.
MG15P

To measure inside small


diameter holes.
MGBH40L
The instrument must suit the job
The instrument must suit the job
The instrument must suit the job
The instrument must suit the job
Automotive Applications
Ball Expanded Bolt Hole

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

-30 0.8 increase

1.7 increase

-40 2.8 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

High Rolli ng P re ssu re


-2 0
R e sidua l Str ess (ksi)

-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

30.0 Pre VSR Avg.


Stress (ksi)

Post VSR Avg.


20.0
Pre TSR Avg.
10.0 Post TSR Avg.
0.0
0 5 10 15 20 25
-10.0
Distance (mm)
Weldments

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!

Stress vs. Depth - Gear


20

-20

-40

-60
Stress (ksi)

-80

-100

-120

-140 Peen Method A


Peen Method B
-160
Unpeened

-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

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