Matthew J. Peel

Distortion control in welding by mechanical tensioning

Abstract This paper investigates the potential of mechanical tensioning (MT) to reduce the magnitude of residual stresses in welds and to eliminate buckling distortion. Both friction stir (FSW) and arc welds have been produced from the aluminium alloy AA2024, with different levels of tensile stress applied along the weld line either during or after welding. The resulting welds have been characterised in terms of out of plane distortion, residual stresses and microstructure. Buckling distortion was eliminated by stretching plates to between 35 and 70% of the yield stress of the material during welding. For each set of welding parameters investigated, an optimum tensioning stress has been identified, which eliminates the tensile residual stress peak across the weld zone, along with distortion. This optimum tensioning stress increases in line with the heat input of the welding process. When MT stresses are increased beyond this optimum value, then distortion arises once more and a band of compressive stress is formed across the weld zone.

In situ study of dynamic recrystallization and hot deformation behavior of a multiphase titanium aluminide alloy

Hot-compression tests were conducted in a high-energy synchrotron x-ray beam to study in situ and in real time microstructural changes in the bulk of a β-solidifying titanium aluminide alloy. The occupancy and spottiness of the diffraction rings have been evaluated in order to access grain growth and refinement, orientation relationships, subgrain formation, dynamic recovery, and dynamic recrystallization, as well as phase transformations. This method has been applied to an alloy consisting of two coexisting phases at high temperature and it was found that the bcc β-phase recrystallizes dynamically, much faster than the hcp α-phase, which deforms predominantly through crystallographic slip underpinned by a dynamic recovery process with only a small component of dynamic recrystallization. The two phases deform to a very large extent independently from each other. The rapid recrystallization dynamics of the β-phase combined with the easy and isotropic slip characteristics of the bcc structure explain the ex...

Linear friction welding of aluminium to copper

Abstract The joining of dissimilar materials is attaining increasing importance as there is a drive to utilise hybrid structures and reduce the weight or cost of products. The present work therefore studied the linear friction welding of commercially pure grades of aluminium to copper (AA 1050 to C101) for potential power transmission applications. Results showed that welds with very good mechanical and electrical properties can be produced. The weld microstructure was analysed using optical microscopy, backscattered scanning electron microscopy, hardness testing and high energy synchrotron X-ray diffraction. These techniques were used in order to identify any cross-weld grain size variations and possible formation of intermetallic phases close to the weld line.

Aspects of residual stress determination using energy-dispersive synchrotron X-ray diffraction

In this paper we discuss certain aspects of residual stress measurements using energy-dispersive synchrotron X-ray diffraction using very high X-ray energies in the range up to 200keV. In particular, we focus on the strain resolution and its relation to the geometric contribution to the instrumental resolution. This energy range together with the brilliance of insertion devices allows measurements in bulk materials with penetration approaching those of neutrons, and the technique is demonstrated to have a high potential for residual stress determination. However, the use of high X-ray energies implies a relatively small diffraction angle and in turn a relatively elongated gauge volume, which favours the application of the technique to essentially 2D problems.

Rupture of Stochastically Occurring Vesicle Clusters Limits Bilayer Formation on Alkane–PEG-Type Supports: Uncoupling Clustering from Surface Coverage

Polymer-supported bilayers (PSBs) are a recognized tool for drug discovery through function-interaction analysis of membrane proteins. While silica-supported bilayers (SSBs) spontaneously form from surface-adsorbed vesicles, successful PSB formation via a similar method has thus far been limited by an insufficient understanding of the underlying vesicle-remodelling processes. Here, we generated a polymer support through the incubation of poly-L-lysine conjugated to alkyl-chain-terminated poly(ethylene)glycol on silica. This polymer-coated silica substrate yielded efficient vesicle adsorption and spontaneous bilayer formation, thereby providing a rare opportunity to address the mechanism of PSB formation and compare it to that of SSB. The combined use of super-resolution imaging, kinetics, and simulations indicates that the rupture of stochastically formed vesicle clusters is the rate-limiting step, which is an order of magnitude higher for silica than for polymer-coated silica. This was confirmed by directly demonstrating increased rupture rates for surface adsorbed multivesicle assemblies formed by vesicle cross-linking in solution. On the basis of this key insight we surmised that a low propensity of cluster rupture can be compensated for by an increase in the number density of clusters: the deposition of a mixture of oppositely charged vesicles resulted in bilayer formation on another alkane-PEG type of interface, which despite efficient vesicle adsorption otherwise fails to support spontaneous bilayer formation. This potentially provides a universal strategy for promoting bilayer formation on resistant surfaces without resorting to modifying the surface itself. Therefore, multivesicle assemblies with tailored geometries not only could facilitate bilayer formation on polymers with interesting functional properties but also could instigate the exploration of vesicle architecture for other processes involving vesicle remodelling such as drug delivery.

Measurement of elastic follow-up for combined applied and residual stresses

Tensile residual stress can reduce the load carrying capability of a structure. However, residual stresses may be redistributed during the life of a component by, for example, permanent deformation. This paper explains an experiment carried out to understand how applied and residual stresses interact and to seek a method of measuring elastic follow-up during the interaction. A friction stir welded aluminium alloy plate was subjected to a series of incrementally increasing load and unload cycles, whilst simultaneously measuring residual stresses and deformation. In-situ loading of the specimen during the residual stress measurements allowed the relaxation of the residual stress to be quantified. The elastic follow-up has been estimated and measured by considering both the structural stiffnesses of the specimen and the relaxation of the residual stress. It was found that global yielding, which can result in no net change of incompatibility, has to be considered when calculating elastic follow-up. An estimation of the elastic follow-up factor based on the structural stiffnesses of the specimen was found to be non-conservative and an elastic follow-up factor of 2.9 was measured. That is three times as much plastic strain is required to relax the residual stress when compared to the fixed-displacement case.Copyright

Dynamic Recovery and Recrystallization during Hot-Working in an Advanced TiAl Alloy

Abstract Intermetallic TiAl alloys are light-weight high-temperature materials and intended to partly replace Ni based alloys in jet engines. Due to difficult forming operations, component prices are high and limit the possible field of application. During hot-working, recovery and recrystallization effects determine the microstructural evolution and thereby the mechanical properties of the finished part as well as its behavior during deformation. To study the occurring phenomena, in-situ diffraction experiments with high-energy X-rays were conducted. By means of this method, the dominating processes were identified. The results were validated through electron back scatter diffraction experiments.

Investigation of the stress fields around a fatigue crack in aluminium alloy 5091

There have been many theoretical studies to predict the stress fields around the tip of a growing fatigue crack. However, until recently the highly-localized, small scale nature of the stresses has meant that direct measurement has not been possible. With the current generation of synchrotron X-ray sources, sub-millimetre sampling dimensions are now possible, and it has become possible to evaluate directly the stresses at the tip of a fatigue crack and to see how the stresses evolve as the result of an overload, for example. In this paper we present results of synchrotron X-ray diffraction analysis of the stress fields around a fatigue crack in aluminium alloy 5091 (Al-Mg-Li-C-O); this is a dispersion-strengthened alloy with a fine grain size, which makes it ideal for such experiments. Compact tension (CT) specimens were prepared with constant amplitude fatigue loading. The energy dispersive X-ray diffraction (EDXRD) technique was used for measuring strains around the crack tip along the mid thickness of the specimen under in-situ loading. The measurement was carried out at the ESRF (European Synchrotron Radiation Facility), Grenoble, France on the ID15A beam line. The experimental crack tip stresses have been compared with the analytical fracture mechanics solution.

An Experimental Procedure to Determine the Interaction between Applied Loads and Residual Stresses

This paper presents a novel experiment to quantify both the initial residual stress state in a specimen and its redistribution due to plasticity induced by in-situ loading. The rate of relaxation of the residual stress with respect to permanent deformation is a measure of the elastic follow-up associated with the residual stress field. Residual stress measurements were made using high energy dispersive X-ray diffraction. Digital image correlation, verified by strain gauges, was used to measure full-field deformation on the specimen. The specimen was loaded and unloaded in-situ incrementally to promote plasticity, allowing the relaxation rate of the residual stress to be quantified. An elastic follow-up factor was calculated for the residual stress field, that indicated loading conditions of the residual stress field between fixed-displacement and fixed-load.

Hot Deformation of Cast and Extruded TiAl: An In Situ Diffraction Study

Intermetallic TiAl alloys are a class of innovative high-temperature materials which are developed to replace the substantially denser Ni-base alloys in low-pressure turbine blades of jet engines. By streamlining the production process of these parts, a substantial decrease in production costs can be achieved. To this end, a profound knowledge of the microstructural processes occurring during hot deformation is a prerequisite. To investigate the microstructural development during forming operations, cast and extruded as well as only cast specimens were hot-deformed and the microstructural development investigated in-situ by means of a novel diffraction method. This powder diffraction method utilizes the behavior of individual reflection spots on the Debye-Scherrer rings for deriving the materials response to the deformation imposed. It was found that the behavior of the two specimens is rather similar, although the starting microstructures show pronounced differences.