ANALYSIS OF RESIDUAL STRESS IN

HARD FACED COMPONENT USING

CONTOUR METHOD
PHASE: I
PRESENTED BY

E.JAMUNA
0572209
M.E., (MANUFACTURING ENGG)

UNDER THE GUIDANCE OF

Mrs. K. MANONMANI,
LECTURER IN MECHANICAL ENGG,
GCT,COIMBATORE 13.

OBJECTIVE

Measurement of residual stress in hardfaced

component (Stellite 6) using Contour Method.

RESIDUAL STRESS

Due to uneven cooling and the local heat input.

Affect both mechanical and metallurgical properties

of welded components.

strong influence on weld deformation, fatigue

strength, fracture toughness and buckling strength.

RESIDUAL STRESS
MEASURING METHODS

Stress Relaxation Methods

Hole drilling method.
Brittle coating method.
Photo elasticity method
Diffraction Methods
X-ray diffraction method
Neutron diffraction method

Dissection method.

RESIDUAL STRESS MEASURING

METHODS

Methods Using Stress Sensitive Properties

Ultrasonic method
Micro magnetic method

CONTOUR METHOD
Powerful Techniques

Uniquely related to to the original residual stresses

Simple

Inexpensive

Equipment widely available

STEPS INVOLVED

Material Selection

Process Selection

Stress Measurement
(i) Specimen Cutting
(ii) Contour Measurement
(iii) Stress Analysis
- Principle
- Material Properties
- Finite Element Model
- Boundry conditions and applied loads
Results and Discussion

MATERIAL SELECTION

Base Metal Low Carbon Steel

Surfacing Metal Stellite 6 (Co Cr- A)

PROCESS SELECTION

SURFACING PROCESSES

CLADDING

HARDFACING Plasma Transferred Arc

Welding

BUILD-UP

BUTTERING

HARDFACING

Metal is deposited over another surface to increase

the hardness ,wear resistance and corrosion
resistance of the surface.

NEED FOR HARDFACING

Better Wear resistance than the original base

metal and increase double and triple the working
life of a component.

Improve Corrosion resistance of the material

surface.

Improve Mechanical and Metallurgical properties of

hardfaced layers.

HARDFACING APPLICATIONS

Valve Industries

Chemical ,refineries & fertilizer plants

Nuclear and steam power plants

Pressure vessels

Agriculture Machines

Earth moving Equipments

Aircraft and Missile Components.

STRESS MEASUREMENT
(i) Specimen Cutting

Make a cut perpendicular to the weld area.

No material removal

WIRE ELECTRIC DISCHARGE MACHINE

(ii) Contour Measurement

By CMM (Co-ordinate Measuring Machine)
MACHINE SPECIFICATION
Model SPECTRA
Probe tip Length 10 mm, Diameter 1 mm
Accuracy 3 microns

(iii) Stress Analysis

Principle

Principle

In step A, the undistributed part is made up of two halves

containing the original residual stresses.

In step B, the part has been cut in two resulting in a

deformation of both surfaces as the residual stresses are
released, resulting in zero normal stresses.

In step C, the material is forced back to its original position.

This involves applying the deformation measured in step b to
an FE model to calculate the corresponding stresses. This
superposition principle assumes that the material behaves
elastically during the relaxation of residual stress and that the
material removal process does not introduce stresses of
sufficient magnitude to affect the measured displacements.

Material Properties

Material 1 (Low Carbon Steel)-Base Metal:

(I) Modulus of elasticity:160 Mpa
(ii) Poissons ratio
: 0.29

Material 2 (Stellite-6)-Powder Material:

(I) Modulus of elasticity: 140 Mpa
(ii) Poissons ratio
: 0.28

Finite Element Model

Measurement points are taken 0.5mm increment

along the width surface, and 1mm increment along
the length side.

By Direct Node Generation.

Total node - 32634

Element - SOLID45.

SOLID45

HARDFACED COMPONENT FEA MODEL

HARDFACED COMPONENT EXPERIMENTS

BOUNDRY CONDITIONS AND

APPLIED LOADS

Arrest 4 corner nodes in bottom side of the

component.
Applied load by displacement measured from CMM.

RESULTS AND DISCUSSIONS

Transverse Stresses
-

Both Tensile and Compressive in nature.

- Graphs are drawn between the node 1 to 32634.

Von Mises stresses in Hardfaced

Component

Von Mises stresses in Hardfaced

Component

Stress Intensity in Hardfaced

Component

Stress Intensity in Hardfaced

Component

Shear stress in XZ direction

Shear stress in XZ direction

CONCLUSION

Affect its mechanical properties, metallurgical

properties and the service life of the component.

Minimize the premature failures.

By direct node generation technique (ANSYS 8.0 ).

High accuracy compared to other technique.

Relatively simple procedure.

No tedious material removal.

By various stress relieving methods

REFERENCES

Huber, A. W. and Beedle, L. S., Residual Stress and

the Compressive
Strength of Steel, Welding
Journal, 33 (12), Research suppl. 589-s (1954).

Ketter, R.L., The influence of residual stress on the

strength of structural member Welding Research
bulletin, No44, 1958

Bueckner, H. F., The Propagation of cracks and the

Energy of Elastic Deformation, Transactions of the
American Society of Mechanical Engineers, Vol. 80,
pp. 1225-1230, 1958.

Tall.L., Residual Stresses in weld plates, a

theoretical study, welding journal, 43, january1964

Enver odar, Fumio Nishino Lambert Tall, Residual

stresses in T-1lConstructional alloy steel plates,
welding research council bulletin,121,April 1967.

Sommer, C. and Sommer, S., Wire EDM Handbook,

Advance Publishing, Inc., Houston, Texas, USA, 1997.

Prime, M. B., Cross Sectional Mapping of Residual

Stresses by Measuring the Surface Contour After a
Cut, Journal of Engineering Materials and
Technology,. Vol. 123, pp. 162-168, 2001l

Prime, M. B and Gonzales,A.R, The contour method

,simple 2D mapping of residual stress,6th Int .Conf on
Residual Stresses,Oxford,U.K,pp617-624,July 2001

Zhang, Y., Fitzpatrick, M. E. and Edwards, L.,

Measurement of Residual Stresses around a cold
Expanded Hole in an EN8 Steel Plate using the Contour
Method, Materials Science Forum, Vols. 404-407, pp.
527-532, 2002.

Lu, J, (ed), Hand book of measurement of residual

stresses, the faurmont Press Inc, Liburn, Georgia, SA,
1996.

Prime, M. B., Hughes, D. J. and Webster, P. J., Weld

Application of a New Method for Cross Sectional
Residual Stress Mapping, Proc. 2001 SEM Annual
Conference on experimental and applied mechanics,
pp608, 611, June2001.

Prime, M. B and Martineau R.L, Mapping residual

stresses after foreign object damage using the
contour method, Materials science Forum, vol404,
407, pp521, 526, 2002

Michael B. Prime, Residual stresses measured in

Quenched HSLA-100 Steel plate, Proceedings of
the 2005 SEM Annual Conference and Exposition
on Experimental and Applied Mechanics, June 7-9,
2001.

Koichi Masubichi, Residual Stress and Distortion,

Metals Hand Book, Ninth Edition, Vol.6, Welding,
Brazing and Soldering, American Society for Metals,
Metals. park, Ohio, U. S. A., pp. 856-895, 1983

P. Palanichamy, A. Joseph, D. K. Battacharya and

Baldev Raj, Residual park, Ohio, U. S. A., pp. 856895, 1983 Stresses and their Evaluationin Welds,
Welding Engineering Handbook, Eds. S.
Soundararajan, S. Vijaya Bhaskar
and G C.
Amarnath Kumar, Radiant Publications Pvt. Ltd.,
Secundrabad, India, Vol. 1, pp. 269-296, 1992.

F. Zandmann and M. R. Wood, Photo Stress,

Product Engineering, 27(9), 167-168, 1956.

J. Lorontzen, Nondestructive Evaluation of

Residual Stress by Neutron Diffraction,
NDT
International, Vol. 21(6), pp. 385-388, 1988.

S. J. Rumble and J. G. Sparrow, Review of Ultrasonic

velocity Methods of Determining residual Stress, report
No. ARL-STRUC-TM-416, Aeronautical Research
Laboratory, Melbourne, Australia, May 1984.

P.V. Grant, 2D Residual Stress Mapping using the

Contour method: A Technical
Review, Los Alamos
Laboratory, 2005.

Robert J. Sebering, Michael R. Hill, Michael B. Prime,

Adrian T Dewald, Vivek
R. Dave and Mark J. Cola,
Residual Stress Mapping in Welds Using the Contour
Method, Trends in Welding Research , Proceedings of
the 6th International Conference April 15-19, 2002, Pine
Mountain, Georgia , ASM International, 2003,pp891-896

THANK YOU