Publications

Development of a Generalized Residual Stress Inversion Technique

Johnson, Kyle J.; Bishop, Joseph E.; Reu, Phillip L.; Walsh, Timothy W.; Farias, Paul A.; Jared, Bradley H.; Susan, D.F.; Rouse, Jerry W.; Whetten, Shaun R.; Chen, Mark J.; Aquino, Wilkins A.; Bellotti, Aurelio B.; Jacobs, Laurence J.

Residual stress is a common result of manufacturing processes, but it is one that is often overlooked in design and qualification activities. There are many reasons for this oversight, such as lack of observable indicators and difficulty in measurement. Traditional relaxation-based measurement methods use some type of material removal to cause surface displacements, which can then be used to solve for the residual stresses relieved by the removal. While widely used, these methods may offer only individual stress components or may be limited by part or cut geometry requirements. Diffraction-based methods, such as X-ray or neutron, offer non-destructive results but require access to a radiation source. With the goal of producing a more flexible solution, this LDRD developed a generalized residual stress inversion technique that can recover residual stresses released by all traction components on a cut surface, with much greater freedom in part geometry and cut location. The developed method has been successfully demonstrated on both synthetic and experimental data. The project also investigated dislocation density quantification using nonlinear ultrasound, residual stress measurement using Electronic Speckle Pattern Interferometry Hole Drilling, and validation of residual stress predictions in Additive Manufacturing process models.