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Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

  • 1.  Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Putnam Service Award
    Posted 09-21-2021 12:22

    I am reaching out again for assistance with the chapter on failure analysis for our Residual Stress Handbook project.  This project is part of the Residual Stress Technical Committee that formed in 2020.

     Many of you have already provided guidance, and I truly appreciate the help.  I have attempted to put together an outline.  Case histories will be covered in a separate chapter.  Together, we can get a solid chapter that will advance knowledge of how residual stresses cause failures and how to detect them.

     Proposed outline:

    1.  The residual stress failure dilemma – The failure often relieves the stresses we are trying to measure
    2. Failures often attributed to residual stress
      1. Quench cracking
      2. Fastener failures
      3. Welding failures
      4. ?
      5. ?
    3. The relationship between residual stress and fatigue
    4. The special cases of stress corrosion cracking and hydrogen embrittlement
    5. Methods to detect residual stress and the applicability to the type of failure
    6. ?
    7. ?

    Please comment/expand/modify the above so we can cover the topic fully.  I would like to see a collaboration between FAS and RSTC.  I feel it would be a win/win for both entities.

    Thank you!
    Beth



    ------------------------------
    Beth Snipes Chapter Council Chair 2020-2021
    Sr. Materials Engineer, FASM
    TEC Materials Testing
    Knoxville TN
    (865) 458-1991
    ------------------------------


  • 2.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Posted 09-22-2021 09:05
    Hi Beth,

    I'm not sure what is covered in other sections of the handbook so these may be covered in other places, but some potential ideas:
    * ways to relieve stresses (thermal and mechanical)
    * ways that residual stresses can actually reduce failures (such as a compressive RS on the surface)
    * failures due to surface RS vs. failures due to RS throughout the part
    * RS can lead to changes in the properties of the material, which can contribute to failures in use (rather than during fabrication as with quench or weld cracking). eg a reduction in ductility makes the part prone to fracture, as opposed to the RS increase the likelihood of cracking specifically.
    * How combinations of RSs in the same part can contribute to failure. 
    * I believe that the application of some coatings can introduce RS that can inhibit the bonding of the coating to the substrate. Similarly, it could affect the bonding of some composite materials.

    Some of those are probably not applicable to this specific chapter, but hopefully some are.


    ------------------------------
    Lindsay Malloy
    Staff Materials Development Engineer
    DePuy Synthes
    West Chester PA
    ------------------------------



  • 3.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Putnam Service Award
    Posted 09-23-2021 10:02
    Lindsay,

    Thank you for the insight.  Some of the topics you raise should be covered in other chapters.  I'll pass along your suggestions to the RS Handbook Sub-committee so everyone benefits.  Thanks again for the input!

    Beth

    ------------------------------
    Beth Snipes Chapter Council Chair 2020-2021
    Sr. Materials Engineer, FASM
    TEC Materials Testing
    Knoxville TN
    (865) 458-1991
    ------------------------------



  • 4.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Posted 09-22-2021 13:41
    Residual stress plays a significant role in determining the fitness for service of crack-like flaws (planar defects) located near welds in welded construction. Residual stress is considered to be a secondary stress. Both BS7910 and ASME/API 579 provide approaches for the analyst to estimate the residual stress for assessment purposes. The Handbook should mention how residual stress is treated by these standards. 





  • 5.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Putnam Service Award
    Posted 6 days ago
    Robert,

    My apologies for not replying sooner.  I had some issues with using Connect.  I am passing your comment along to the committee so we can make sure we discuss the topic in the handbook under the most relevant division.

    Regards,
    Beth

    ------------------------------
    Beth Snipes Chapter Council Chair 2020-2021
    Sr. Materials Engineer, FASM
    TEC Materials Testing
    Knoxville TN
    (865) 458-1991
    ------------------------------



  • 6.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Posted 09-23-2021 10:18
    I see you mentioned quench cracking, but possibly include something about RS causing distortion in heat treat.

    ------------------------------
    Ken Kirby
    Snap-on, Inc.
    Kenosha WI
    (262) 748-3836
    ------------------------------



  • 7.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Posted 09-24-2021 11:17
    You should devote a chapter to RS development after surface hardening either by induction or by termochemical treatment, if you do not cover already the issue in the chapter on the relationship between RS and Fatigue.
    Also Residual Stresses due to machining should be addressed somewhere.

    ------------------------------
    Donato FIRRAO FASM
    Professor
    Politecnico di Torino
    TORINO
    +393351494032
    Italy
    ------------------------------



  • 8.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Posted 30 days ago
    Would you consider reaching out to Lambda Research?  Seems like they would be interested in helping out.

    ------------------------------
    Aaron Slager
    Bell Helicopter Textron
    Fort Worth TX
    ------------------------------



  • 9.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Putnam Service Award
    Posted 6 days ago
    Aaron,

    I believe that a Lambda person is on our Residual Stress Technical Committee.  We have asked for volunteers to work on the Handbook Sub-Committee.

    Regards,
    Beth

    ------------------------------
    Beth Snipes Chapter Council Chair 2020-2021
    Sr. Materials Engineer, FASM
    TEC Materials Testing
    Knoxville TN
    (865) 458-1991
    ------------------------------



  • 10.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Putnam Service Award
    Posted 6 days ago
    Prof. Firrao,

    I will pass along your comments to the committee.  I believe that RS development will be covered in a separate section.  The failure analysis section is the appropriate place to cover RS and fatigue.

    Regards,
    Beth

    ------------------------------
    Beth Snipes Chapter Council Chair 2020-2021
    Sr. Materials Engineer, FASM
    TEC Materials Testing
    Knoxville TN
    (865) 458-1991
    ------------------------------



  • 11.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Putnam Service Award
    Posted 6 days ago
    Ken,

    Thank you for the input!  I have added warpage to the outline.  I believe that heat treat distortion would fall under this topic.

    Regards,
    Beth

    ------------------------------
    Beth Snipes Chapter Council Chair 2020-2021
    Sr. Materials Engineer, FASM
    TEC Materials Testing
    Knoxville TN
    (865) 458-1991
    ------------------------------



  • 12.  RE: Residual Stress Handbook - Chapter on Failure Analysis and Residual Stress

    Posted 5 days ago

    Hi Beth,

     

    In addition to warpage in heat treatment (due to residual stress from casting or previous processes), distortion can also occur during machining due to residual stress from heat treatment, and after failure, which can affect the failure investigation. Residual stresses can also be introduced by the failure if the distortion is severe enough and introduced or relieved if the failure involved high temperatures.

     

    Best Regards,

    GIW Industries, Inc. (A KSB Company)
    Advanced Manufacturing Engineer – Metallurgy & Foundry Systems


    Paul Taylor

    5000 Wrightsboro Road
    Grovetown, Ga 30813
    Tel.: +1 706-863-1011 ext 2559
    Fax: +1 706-868-8025
    Email: paul.taylor@ksb.com

    http://www.giwindustries.com