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Stress-relief heat treating is used to relieve residual stresses in materials that develop during manufacturing processes like welding, forming, and machining. It involves uniformly heating the material to a temperature below its transformation range, holding for a period of time, then uniformly cooling. This allows microscopic creep to occur and reduce stresses. The level of stress relief depends on time, temperature, and the material's resistance to creep. Higher temperatures or longer times are needed to relieve stresses in creep-resistant alloys. Stress-relief heat treating is commonly used to reduce residual stresses in steels and copper alloys.
Stress-relief heat treating is used to relieve residual stresses in materials that develop during manufacturing processes like welding, forming, and machining. It involves uniformly heating the material to a temperature below its transformation range, holding for a period of time, then uniformly cooling. This allows microscopic creep to occur and reduce stresses. The level of stress relief depends on time, temperature, and the material's resistance to creep. Higher temperatures or longer times are needed to relieve stresses in creep-resistant alloys. Stress-relief heat treating is commonly used to reduce residual stresses in steels and copper alloys.
Stress-relief heat treating is used to relieve residual stresses in materials that develop during manufacturing processes like welding, forming, and machining. It involves uniformly heating the material to a temperature below its transformation range, holding for a period of time, then uniformly cooling. This allows microscopic creep to occur and reduce stresses. The level of stress relief depends on time, temperature, and the material's resistance to creep. Higher temperatures or longer times are needed to relieve stresses in creep-resistant alloys. Stress-relief heat treating is commonly used to reduce residual stresses in steels and copper alloys.
Introduction STRESS-RELIEF HEAT TREATING is used to relieve stresses that remain locked in a structure as a consequence of a manufacturing sequence. This definition separates stress-relief heat treating from postweld heat treating in that the goal of postweld heat treating is to provide, in addition to the relief of residual stresses, some preferred metallurgical structure or properties (Ref 1, 2). For example, most ferritic weldments are given postweld heat treatment to improve the fracture toughness of the heat- affected zones (HAZ). Moreover, austenitic and nonferrous alloys are frequently postweld heat treated to improve resistance to environmental damage. Stress-relief heat treating is the uniform heating of a structure, or portion thereof, to a suitable temperature below the transformation range (Ac1 for ferritic steels), holding at this temperature for a predetermined period of time, followed by uniform cooling (Ref 2, 3). Care must be taken to ensure uniform cooling, particularly when a component is composed of variable section sizes. If the rate of cooling is not constant and uniform, new residual stresses can result that are equal to or greater than those that the heat-treating process was intended to relieve. Stress- relief heat treating can reduce distortion and high stresses from welding that can affect service performance. The presence of residual stresses can lead to stress-corrosion cracking (SCC) near welds and in regions of a component that has been cold strained during processing. Furthermore, cold strain per se can produce a reduction in creep strength at elevated temperatures. Residual stresses in a ferritic steel cause significant reduction in resistance to brittle fracture. In a material that is not prone to brittle fracture, such as an austenitic stainless steel, residual stresses can be sufficient to provide the stress necessary to promote SCC even in environments that appear to be benign (Ref 4). Sources of Residual Stress There are many sources of residual stress; they can occur during processing of the material from ingot to final product form (Ref 4, 5). Residual stresses can be generated during rolling, casting, or forging; during forming operations such as shearing, bending, drawing, and machining; and during fabrication, in particular, welding. Residual stresses are present whenever a component is stressed beyond its elastic limit and plastic flow occurs. Additional information on residual stresses can be found in the article "Defects and Distortion in Heat-Treated Parts" in this Volume. Bending a bar during fabrication at a temperature where recovery cannot occur (cold forming, for example) will result in one surface location containing residual tensile stresses, whereas a location 180 away will contain residual compressive stresses (Ref 6). Quenching of thick sections results in high residual compressive stresses on the surface of the material. These high compressive stresses are balanced by residual tensile stresses in the internal areas of the section (Ref 7). Grinding is another source of residual stresses; these can be compressive or tensile in nature, depending on the grinding operation. Although these stresses tend to be shallow in depth, they can cause warping of thin parts (Ref 8). Welding. The cause of residual stresses that has received the most attention in the open literature is welding. The residual stresses associated with the steep thermal gradient of welding can occur on a macroscale over relatively long distances (reaction stresses) or can be highly localized (microscale) (Fig. 1). Welding usually results in localized residual stresses that approach levels equal to or greater than the yield strength of the material at room temperature. Alleviation of Residual Stresses A number of factors influence the relief of residual stresses, including level of stress, permissible (or practicable) time for their relief, temperature, and metallurgical stability. Time-Temperature Factors. The relief of residual stresses is a time-temperature-related phenomenon (Fig. 2), parametrically correlated by the Larson-Miller equation: Thermal effect = T(log t + 20)10-3 (Eq 1) where T is temperature (Rankin), and t is the time in hours. It is evident in Fig. 2 that similar relief of residual stresses can be achieved by holding a component for longer periods at a lower temperature. For example, holding a piece at 595 C (1100 F) for 6 h provides the same relief of residual stress as heating at 650 C (1200 F) for 1 h. Alloy Considerations. Relief of residual stresses represents typical stress-relaxation behavior, in which the material undergoes microscopic (sometimes even macroscopic) creep at the stress-relief temperature. Creep-resistant materials, such as the chromium-bearing low-alloy steels and the chromium-rich high-alloy steels, normally require higher stressrelief heat-treating temperatures than conventional low-alloy steels. Typical stress-relief temperatures for low-alloy ferritic steels are between 595 and 675 C (1100 and 1250 F). For high-alloy steels, these temperatures may range from 900 to 1065 C (1650 to 1950 F). For high-alloy steels, such as the austenitic stainless steels, stress relieving is sometimes done at temperatures as low as 400 C (750 F). However, at these temperatures, only modest decreases in residual stress are achieved. Residual stresses can be significantly reduced by stress-relief heat treating those austenitic materials in the temperature range from 480 to 925 C (900 to 1700 F). At the higher end of this range, nearly 85% of the residual stresses may be relieved. Stress- relief heat treating in this range, however, may result in sensitizing susceptible material. This metallurgical effect can lead to SCC in service (Ref 9). Frequently, solution-annealing temperatures of about 1065 C (1950 F) are used to achieve a reduction of residual stresses to acceptably low values. Some copper alloys may fail by SCC due to the presence of residual stresses. These stresses are usually relieved by mechanical or thermal stress-relief treatments. Stress-relief heat treating tends to be favored because it is more controllable, less costly, and also provides a degree of dimensional stability. Stress-relief heat treating of copper alloys is usually carried out at relatively low temperatures, in the range from 200 to 400 C (390 to 750 F) (Ref 5). Resistance of a material to the reduction of its residual stresses by thermal treatment can be estimated with a knowledge of the influence of temperature on its yield strength. Figure 3 provides a summary of the yield strength to temperature relationship for three generic classes of steels. The room-temperature yield strength of these materials provides an excellent estimate of the level of localized residual stress that can be present in a structure. To relieve the residual stress requires that the component be heated to a temperature where its yield strength approaches a value that corresponds to an acceptable level of residual stress. Holding at this temperature can further reduce the residual stress through the reduction of strain due to creep. Uniform cooling after residual- stress heat treating is mandatory if these levels of residual stress are to be maintained.
(Doi 10.1016 - B978-0!08!096532-1.01209-7) Ericsson, T. - Comprehensive Materials Processing - Residual Stresses Produced by Quenching of Martensitic Steels