Joe Kelleher

The Measurement of Residual Stress in Railway Rails by Diffraction and other Methods

Residual stresses have been measured in a new roller-straightened railway rail and a worn ex-service rail. Synchrotron {211} lattice strain measurements at ID11 (ESRF) were used to map in-plane components of the stress tensor acting in cross-sectional rail slices. Stress maps made using laboratory X-rays and the magnetic measurement system MAPS, although coarser in detail, show similar trends. The validity of the measured data was examined using a stress balance requirement. Whilst generally true (to ±15 MPa), stress balancing was worst (±50 MPa) in regions with significant plastic deformation, suggesting that the measured {211} lattice strain had become uncharacteristic of the bulk elastic strain. Attributable to plastic anisotropy, this is a well-established issue with diffraction-based stress determination. To complement the in-plane stress measurements, the contour method was used to map the longitudinal stress component in a similar new rail sample, this component being relieved in the slices. On the...

Effect of interpass temperature on residual stresses in multipass welds produced using low transformation temperature filler alloy

Abstract Weld filler alloys that exploit transformation plasticity through low austenite to martensite transformation temperatures offer an effective method of reducing residual stresses in strong steel welds. However, in multipass welds, the heat input from later weld passes may be insufficient to retransform prior welding passes, leading to the accumulation of thermally induced strains and elevated residual stresses. In this work, the residual stress distributions produced around arc welds fabricated with a martensitic weld filler alloy that transforms at a low temperature have been studied as a function of the number of passes deposited and the interpass temperature. It is found that when the interpass temperature is above the transformation temperature of the weld metal, the entire multipass weld transforms as a single entity, thus permitting the optimum exploitation of the transformation plasticity. In contrast, the deposition of new metal with a relatively low interpass temperature leads to increased residual stresses in the underlying layers, reducing or eliminating the beneficial stress states previously created.

Effects of dilution and baseplate strength on stress distributions in multipass welds deposited using low transformation temperature filler alloys

Abstract Transformation plasticity can be utilised to control residual stresses in steel welds. This requires special filler alloys that transform at a sufficiently low temperature to compensate for accumulated thermal contraction strains. However, the welding parameters needed to optimise the effect in multipass joints have yet to be established. This topic has been investigated by characterising the residual stress distribution in multipass welds fabricated with different welding alloys and baseplates using neutron diffraction to assess the effects of dilution and baseplate strength. While the use of richly alloyed weld metal does enhance fatigue performance in single pass joints, the extent of stress relief that can be derived from transformation plasticity is reduced due to incomplete martensitic transformation when further layers are deposited. For all cases studied, compressive stresses were measured in the weld metal with balancing tensile stress in the heat affected zone of the plate. The magnitude of the tension was observed to be a function of the strength of the baseplate. Recommendations are also presented for the combination of welding and material parameters that lead to the optimum exploitation of transformation plasticity as a method for boosting the fatigue performance of multipass welded joints.

Materials analysis opportunities on the new neutron imaging facility IMAT@ISIS

A new neutron imaging and diffraction facility, called IMAT, is currently being commissioned at the ISIS pulsed neutron spallation source. IMAT will take advantage of neutron time-of-flight measurement techniques for flexible neutron energy selection and effective energy discrimination. The instrument will be completed and commissioned within the next few months, after neutrons have been recently delivered to the sample area. From 2016 IMAT will enable white-beam neutron radiography and tomography as well as energy-dependent neutron imaging. The facility will offer a spatial resolution down to 50 microns for a field of view of up to 400 cm2. IMAT will be operated as a user facility for material science applications and will be open for developments of time-of-flight imaging methods.

Texture analysis with a time‐of‐flight neutron strain scanner

A time-of-flight (TOF) neutron strain scanner is a white-beam instrument optimized to measure diffractograms at precise locations within bulky specimens, typically along two perpendicular sample orientations. Here, a method is proposed that exploits the spatial resolution (∼1 mm) provided by such an instrument to determine in a nondestructive manner the crystallographic texture at selected locations within a macroscopic object. The method is based on defining the orientation distribution function (ODF) of the crystallites from several incomplete pole figures, and it has been implemented on ENGIN-X, a neutron strain scanner at the ISIS facility in the UK. This method has been applied to determine the texture at different locations of Al alloy plates welded along the rolling direction and to study a Zr2.5%Nb pressure tube produced for a CANDU nuclear power plant. For benchmarking, the results obtained with this instrument for samples of ferritic steel, copper, Al alloys and Zr alloys have been compared with measurements performed using conventional X-ray diffractometers and more established neutron techniques. For cases where pole figure coverage is incomplete, the use of TOF neutron transmission measurements simultaneously performed on the specimens is proposed as a simple and powerful test to validate the resulting ODF.

High pressure rolling of low carbon steel weld seams: Part 2 – Roller geometry and residual stress

Abstract Large residual stresses are an undesirable but inevitable side effect of fusion welding operations, and localised high pressure rolling of the weld seam is a proposed method for eliminating them. In this study, neutron diffraction has been used to map the residual stresses within low carbon steel weld seams treated with high pressure rolling. The effect on the residual stress distribution of using different roller types was determined, along with the influence of these different rollers on final weld seam geometry. Rolling was found to completely change the residual stress state in the weld, creating large compressive longitudinal residual stresses. It was effective for this purpose regardless of whether it was applied directly to the weld seam or to regions either side of it. The fatigue life of welded specimens was shown to be reduced by rolling; however, it is suggested that this is due to geometric and metallurgical effects.

Effect of stress on NiO reduction in solid oxide fuel cells: a new application of energy-resolved neutron imaging

Recently, two new phenomena linking stress field and reduction rates in anode-supported solid oxide fuel cells (SOFCs) have been demonstrated, so-called accelerated creep during reduction and reduction rate enhancement and nucleation due to stress (Frandsen et al., 2014). These complex phenomena are difficult to study and it is demonstrated here that energy-resolved neutron imaging is a feasible technique for combined mechanics-chemical composition studies of SOFC components, including commercially produced ones. Cermet anode supports, which prior to the measurements were reduced under varying conditions such as different temperatures, various times and different values of applied stress, have been measured. Thus, samples with different contents (and gradients) of Ni and NiO phases were investigated. The first Bragg edge transmission neutron measurements applied for the studies of the reduction progress in these samples were performed at two neutron beamline facilities (ISIS in the UK, Helmholtz Zentrum Berlin in Germany). The obtained results demonstrate the possibility to image and distinguish NiO and Ni phases within SOFC anode supports by energy-resolved neutron imaging and the potential of the neutron imaging method for in situ studies of reduction processes. (Less)

Calculations of single crystal elastic constants for yttria partially stabilised zirconia from powder diffraction data

Yttria Stabilised Zirconia (YSZ) is a tough, phase-transforming ceramic that finds use in a wide range of commercial applications from dental prostheses to thermal barrier coatings. Micromechanical modelling of phase transformation can deliver reliable predictions in terms of the influence of temperature and stress. However, models must rely on the accurate knowledge of single crystal elastic stiffness constants. Some techniques for elastic stiffness determination are well-established. The most popular of these involve exploiting frequency shifts and phase velocities of acoustic waves. However, the application of these techniques to YSZ can be problematic due to the micro-twinning observed in larger crystals. Here, we propose an alternative approach based on selective elastic strain sampling (e.g., by diffraction) of grain ensembles sharing certain orientation, and the prediction of the same quantities by polycrystalline modelling, for example, the Reuss or Voigt average. The inverse problem arises consisting of adjusting the single crystal stiffness matrix to match the polycrystal predictions to observations. In the present model-matching study, we sought to determine the single crystal stiffness matrix of tetragonal YSZ using the results of time-of-flight neutron diffraction obtained from an in situ compression experiment and Finite Element modelling of the deformation of polycrystalline tetragonal YSZ. The best match between the model predictions and observations was obtained for the optimized stiffness values of C11 = 451, C33 = 302, C44 = 39, C66 = 82, C12 = 240, and C13 = 50 (units: GPa). Considering the significant amount of scatter in the published literature data, our result appears reasonably consistent.

Determination and mitigation of the uncertainty of neutron diffraction measurements of residual strain in large-grained polycrystalline material

For large-grained samples it is advantageous to perform pairs of neutron diffraction measurements at the same spatial location but rotated 180° around the geometric centre of the gauge volume as a means of minimizing the scatter coming from the random positioning of grains within the gauge volume.

Sample environment for neutron scattering measurements of internal stresses in engineering materials in the temperature range of 6 K to 300 K

Internal stresses in materials have a considerable effect on material properties including strength, fracture toughness, and fatigue resistance. The ENGIN-X beamline is an engineering science facility at ISIS optimized for the measurement of strain and stress using the atomic lattice planes as a strain gauge. Nowadays, the rapidly rising interest in the mechanical properties of engineering materials at low temperatures has been stimulated by the dynamic development of the cryogenic industry and the advanced applications of the superconductor technology. Here we present the design and discuss the test results of a new cryogenic sample environment system for neutron scattering measurements of internal stresses in engineering materials under a load of up to 100 kN and in the temperature range of 6 K to 300 K. Complete cooling of the system starting from the room temperature down to the base temperature takes around 90 min. Understanding of internal stresses in engineering materials at cryogenic temperatures is vital for the modelling and designing of cutting-edge superconducting magnets and other superconductor based applications.