Residual Stress Evolution during Manufacture of Aerospace Forgings

J. Rolph; M. Preuss; N. Iqbal; M. Hofmann; S. Nikov; M. C. Hardy; M. G. Glavicic; R. Ramanathan; A. Evans

doi:10.1002/9781118516430.ch97

Residual Stress Evolution during Manufacture of Aerospace Forgings

J. Rolph, M. Preuss, N. Iqbal, M. Hofmann, S. Nikov, M. C. Hardy, M. G. Glavicic, R. Ramanathan, A. Evans

Research output: Chapter in Book/Report/Conference proceeding › Chapter › peer-review

9 Citations (Scopus)

Abstract

The residual stresses present through the quenching, ageing, and machining processes in sub-scale forgings of RR1000 have been measured experimentally using neutron diffraction, and the contour method. The forgings, 88.9mm in diameter, and 25.4- 50.8mm thickness, were of small enough geometry to allow neutron strain measurement in 3 directions throughout most of the bulk. The contour method was employed successfully to generate a full 2D map of the hoop stress in the as-aged and machined samples. The two experimental data sets have been shown to agree very well. Finite element modelling predictions based on an experimentally derived heat transfer coefficient (HTC) curve allowed further comparison and generated additional data. Agreement between the experimental and simulated data was found to be reasonable with some discrepancy visible in the axial direction. The water quenching process was found to generate peak stresses up to 1400MPa in the hoop and radial direction, which were relaxed by as much as 700MPa through ageing. Material removal by machining had a less significant impact in most cases, relaxing residual stress by 100-200MPa.

Original language	English
Title of host publication	Superalloys 2012
Editors	Eric S. Huron, Roger S. Reed, Mark C. Hardy, Michael J. Mills, Rick E. Montero, Pedro D. Portella, Jack Telesman
Publisher	Wiley
Pages	881-891
Number of pages	11
ISBN (Print)	9780470943205
DOIs	https://doi.org/10.1002/9781118516430.ch97
Publication status	Published - 2 Oct 2012
Externally published	Yes
Event	12th International Symposium on Superalloys, Superalloys 2012 - Seven Springs, PA, United States Duration: 9 Sept 2012 → 13 Sept 2012 https://www.tms.org/Meetings/Specialty/superalloys2012/home.aspx

Conference

Conference	12th International Symposium on Superalloys, Superalloys 2012
Country/Territory	United States
City	Seven Springs, PA
Period	9/09/12 → 13/09/12
Internet address	https://www.tms.org/Meetings/Specialty/superalloys2012/home.aspx

Keywords

Contour method
Finite element modelling
Neutron diffraction
Nickel superalloy
Residual stress

ASJC Scopus subject areas

Materials Science(all)
Condensed Matter Physics

Access to Document

10.1002/9781118516430.ch97

Cite this

Rolph, J., Preuss, M., Iqbal, N., Hofmann, M., Nikov, S., Hardy, M. C., Glavicic, M. G., Ramanathan, R., & Evans, A. (2012). Residual Stress Evolution during Manufacture of Aerospace Forgings. In E. S. Huron, R. S. Reed, M. C. Hardy, M. J. Mills, R. E. Montero, P. D. Portella, & J. Telesman (Eds.), Superalloys 2012 (pp. 881-891). Wiley. https://doi.org/10.1002/9781118516430.ch97

Rolph, J, Preuss, M, Iqbal, N, Hofmann, M, Nikov, S, Hardy, MC, Glavicic, MG, Ramanathan, R & Evans, A 2012, Residual Stress Evolution during Manufacture of Aerospace Forgings. in ES Huron, RS Reed, MC Hardy, MJ Mills, RE Montero, PD Portella & J Telesman (eds), Superalloys 2012. Wiley, pp. 881-891, 12th International Symposium on Superalloys, Superalloys 2012, Seven Springs, PA, United States, 9/09/12. https://doi.org/10.1002/9781118516430.ch97

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N2 - The residual stresses present through the quenching, ageing, and machining processes in sub-scale forgings of RR1000 have been measured experimentally using neutron diffraction, and the contour method. The forgings, 88.9mm in diameter, and 25.4- 50.8mm thickness, were of small enough geometry to allow neutron strain measurement in 3 directions throughout most of the bulk. The contour method was employed successfully to generate a full 2D map of the hoop stress in the as-aged and machined samples. The two experimental data sets have been shown to agree very well. Finite element modelling predictions based on an experimentally derived heat transfer coefficient (HTC) curve allowed further comparison and generated additional data. Agreement between the experimental and simulated data was found to be reasonable with some discrepancy visible in the axial direction. The water quenching process was found to generate peak stresses up to 1400MPa in the hoop and radial direction, which were relaxed by as much as 700MPa through ageing. Material removal by machining had a less significant impact in most cases, relaxing residual stress by 100-200MPa.

AB - The residual stresses present through the quenching, ageing, and machining processes in sub-scale forgings of RR1000 have been measured experimentally using neutron diffraction, and the contour method. The forgings, 88.9mm in diameter, and 25.4- 50.8mm thickness, were of small enough geometry to allow neutron strain measurement in 3 directions throughout most of the bulk. The contour method was employed successfully to generate a full 2D map of the hoop stress in the as-aged and machined samples. The two experimental data sets have been shown to agree very well. Finite element modelling predictions based on an experimentally derived heat transfer coefficient (HTC) curve allowed further comparison and generated additional data. Agreement between the experimental and simulated data was found to be reasonable with some discrepancy visible in the axial direction. The water quenching process was found to generate peak stresses up to 1400MPa in the hoop and radial direction, which were relaxed by as much as 700MPa through ageing. Material removal by machining had a less significant impact in most cases, relaxing residual stress by 100-200MPa.

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ER -

Residual Stress Evolution during Manufacture of Aerospace Forgings

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Keywords

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