Skip to main content
SpringerLink
Log in

Validating quench stresses in complex aluminium components

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presents results from a numerical and experimental investigation motivated by the need to explore the effectiveness of residual stress relief techniques in aluminium alloy engineering components of complex geometry. Quenching is part of the heat treatment to establish mechanical properties. It can create high levels of residual stress in an engineering component. Finite element analysis (FEA) was used to predict the residual stresses generated by quenching and the location of peak residual stresses corresponding to probable in service failure sites. The residual strains and stresses were characterised using neutron diffraction techniques in components with high and low quench stresses to validate a FEA study, and also to appraise the evolution of a commercial stress relief method. An excellent correlation existed between the simulations and measurements.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22

Similar content being viewed by others

Data availability

Data and material are not provided with the article.

References

  1. ABAQUS (2012) Analysis User’s Manual. Version 6.12, Dassault Systemes Simulia, Inc.

  2. Bray DP et al (2007) Use of ABAQUS for the Simulation of Manufacturing Processes. ABAQUS Users Conference, Paris

    Google Scholar 

  3. Fitzpatrick, M.E., & Lodini, A. (Eds.) (2003) Analysis of Residual Stress by Diffraction using Neutron and Synchrotron Radiation (1st ed.). CRC Press. https://doi.org/10.1201/9780203608999

  4. Hossain S (2005) Residual stresses under conditions of high triaxiality, Ph.D. Thesis, University of Bristol, UK. Available at: https://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.424402

  5. Hossain S, Truman CE, Smith DJ, Peng RL, Stuhr U (2007) A study of the generation and creep relaxation of triaxial residual stresses in stainless steel. Int J Solids Struct 44:3004–3020

    Article  Google Scholar 

  6. Hutchings MT, Withers PJ, Holden TM, Lorentzen T (2005) Introduction to the characterisation of residual stress by neutron diffraction. CRC Press, Boca Raton, p 424

    Book  Google Scholar 

  7. James MN (2011) Residual stress influences on structural reliability. Eng Fail Anal 18(8):1909–1920. https://doi.org/10.1016/j.engfailanal.2011.06.005

    Article  Google Scholar 

  8. Lewis SJ et al (2011, 2011) Determination of Remnant Residual Stresses in Fracture Toughness Specimens Extracted From Large Components. 47(1):e333–e343. https://doi.org/10.1111/j.1475-1305.2009.00614.x

  9. Pan R, Pirling T, Zheng J, Lin J, Davies CM (2019) Quantification of thermal residual stresses relaxation in AA7xxx aluminium alloy through cold rolling. J Mater Process Technol 264:454–468

    Article  Google Scholar 

  10. Ramesh G, Narayan Prabhu K (2016) Effect of Polymer Concentration on Wetting and Cooling Performance During Immersion Quenching. Metall Mater Trans B 47:859–881. https://doi.org/10.1007/s11663-015-0541-5

    Article  Google Scholar 

  11. Robinson, J. (2007) Measurement of the heat transfer coefficient during quenching of the aluminium alloy 7449, Internal COMPACT deliverable report D2a.1.2, Unpublished

  12. Sen S, Aksakal B, Ozel A (2000) Transient and residual thermal stresses in quenched cylindrical bodies. Int J Mech Sci 42:2013–2029

    Article  Google Scholar 

  13. Senatorova OG, Sidelnikov VV, Mihailova IF, Fridlyander IN, Bedarev AS, Spector JI, Tihonova LA (2002) Low Distortion Quenching of Aluminium Alloys in Polymer Medium. Mater Sci Forum 396–402:1659–1664. https://doi.org/10.4028/www.scientific.net/msf.396-402.1659

    Article  Google Scholar 

  14. Song J, Zhang Y (2016) Effect of vibratory stress relief on fatigue life of aluminum alloy 7075- T651. Adv Mech Eng 8(6):1–9. https://doi.org/10.1177/1687814016654379

    Article  Google Scholar 

  15. Stuhr U (2005) Time of flight diffraction with multiple pulse overlap; Part I: the concept. Nucl Instrum Methods A 545:319–329

    Article  Google Scholar 

  16. Stuhr U, Grosse M, Wagner W (2006) The TOF-strain scanner POLDI with multiple frame overlap—concept and performance. Mater Sci Eng A 437(1):134–138. https://doi.org/10.1016/j.msea.2006.04.069

    Article  Google Scholar 

  17. Withers PJ (2007) Residual stress and its role in failure. Rep Prog Phys 70(12):2211–2264. https://doi.org/10.1088/0034-4885/70/12/R04

    Article  Google Scholar 

  18. Yang Y (2009) Understanding of Vibration Stress Relief with Computation Modeling. J Mater Eng Perform 18:856–862. https://doi.org/10.1007/s11665-008-9310-9

    Article  Google Scholar 

  19. Zainulabdeen AA et al (2018) IOP Conference Series: Materials Science and Engineering, vol 454. International Conference on Materials Engineering and Science, Istanbul

    Google Scholar 

  20. Zheng J-H, Pan R, Wimpory RC, Lin J, Li C, Davies CM (2019) A novel manufacturing process and validated predictive model for high-strength and low-residual stresses in extra-large 7xxx panels. Mater Des 173:107767

    Article  Google Scholar 

Download references

Acknowledgements

For this work, we are grateful for the use of the experimental facilities at SINQ, Paul Scherrer Institute. This research project has been supported by the European Commission under the 6th Framework Programme through the Key Action: Strengthening the European Research Area, Research Infrastructures. Contract number: RII3-CT-2003-505925.

Funding

This research has been supported by the European Commission under the 6th Framework Programme through the Key Action: Strengthening the European Research Area, Research Infrastructures. Contract number: RII3-CT-2003-505925.

Author information

Authors and Affiliations

  1. Department of Aeronautical Engineering, Military Technological College, Muscat, Oman

    Sayeed Hossain

  2. Laboratory for Neutron Scattering and Imaging, Paul Scherrer Institute, CH-5232, Villigen, PSI, Switzerland

    Uwe Stuhr

  3. School of Engineering, University of Limerick, Limerick, Ireland

    Jeremy S. Robinson

  4. Department of Mechanical Engineering, University of Bristol, Queen’s Building, University Walk, Bristol, BS8 1TR, UK

    Christopher E. Truman

Authors
  1. Sayeed Hossain
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Uwe Stuhr
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jeremy S. Robinson
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Christopher E. Truman
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

By comparing numerical prediction with experimentally measured stresses by neutron diffraction technique, the finite element analysis (FEA) study was validated, and the effectiveness of stress relief technique explored. FEA predicted the residual stress generated by quenching and the location of peak residual stresses corresponding to probable failure sites.

Corresponding author

Correspondence to Sayeed Hossain.

Ethics declarations

Code availability

Not applicable

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hossain, S., Stuhr, U., Robinson, J.S. et al. Validating quench stresses in complex aluminium components. Int J Adv Manuf Technol 113, 3555–3567 (2021). https://doi.org/10.1007/s00170-021-06831-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06831-y

Keywords

Search

Navigation