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Measurement of Residual Stress Using the Ultrasonic Method in Aluminum Welding: FE Analysis and Experimental Study

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Abstract

Nowadays, measuring residual stress in welded parts is of great importance in the industry. Based on the measured residual stress and the operational conditions of the part, a suitable factor of safety is defined for the design. Destructive methods have most often been used to determine residual stresses. Given limitations such as high cost, non-destructive testing (NDT) methods have replaced destructive methods in recent years. The ultrasonic method has attracted much attention in recent years for determining residual stress. In addition to its simplicity, low cost, and the need for only a few pieces of equipment, this method has additional advantages such as the ability to measure residual stress at various depths. In this paper, the feasibility of the ultrasonic method in measuring residual stress in the fusion welding of two aluminum sheets was studied and compared with the simulation result. The longitudinal residual stress was measured using the ultrasonic method via 1, 2, 4, and 5 MHz transducers at a depth near the surface. An ultrasonic wedge based on Snell’s equation was built to create the LCR wave and transmit it into the part. Next, the results obtained from the ultrasonic measurement were compared with those obtained through the numerical simulation in Abaqus software. Overall, it was found that the ultrasonic simulation method could predict with high accuracy the residual stress at various depths of the part. Furthermore, the results demonstrated that the accuracy of this method declined with an increase in the ultrasonic frequency.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Azad University of Arak, Arak, Iran

    Ali Ebrahimi

  2. Department of Mechanical Engineering, University of Kashan, Kashan, Iran

    Masuod Bayat

  3. Department of Mechanical Engineering, Arak University of Technology, Arak, Iran

    Emad Norouzi

Authors
  1. Ali Ebrahimi
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  2. Masuod Bayat
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  3. Emad Norouzi
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Correspondence to Masuod Bayat.

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Ali Ebrahimi, Bayat, M. & Norouzi, E. Measurement of Residual Stress Using the Ultrasonic Method in Aluminum Welding: FE Analysis and Experimental Study. Russ J Nondestruct Test 57, 669–678 (2021). https://doi.org/10.1134/S1061830921080027

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  • DOI: https://doi.org/10.1134/S1061830921080027

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