Residual Stress Characterization for Marine Gear Cases in As-Cast and T5 Heat Treated Conditions with Application of Neutron Diffraction

Stroh, Joshua; Sediako, D.

doi:10.1007/978-3-030-05864-7_50

Cited by 3 publications

(5 citation statements)

References 4 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The T5 reference sample showed slightly greater properties compared to the as-cast reference sample, which could be correlated to the small increase in Al 15 (Mn,Fe) 3 Si 2 and decrease in Al 8 FeMg 3 Si 6 ; however, this trend is not consistent for the other samples; (3). The near-equal tensile performance and similar microstructures observed for both gearcases suggests that the alleviation of residual stress, that was observed in the preliminary stress analysis [7], following heat treatment was primarily caused by temperature-induced plasticity that occurred in the material during the elevated temperature solutionizing or precipitation stage of the heat treatment. It is likely that the high magnitude of residual stress (~120 MPa) that was present in the gearcase exceeded the temperature-dependent yield strength of the A362 alloy, leading to a stress release via plasticity.…”

Section: Discussionmentioning

confidence: 54%

“…However, the heat treatment led to a slightly greater volume fraction of intermetallics, specifically (Mn,Fe) 3 Si 2 compound, through the addition of Mn or modified cooling rates, the stress concentrations in the material decrease, and as a result, the tensile performance generally improves. Although some microstructural changes were observed, the differences between the as-cast and T5 gearcase are minor and thus are not presumed to be correlated to the alleviation of residual stress described the previous stress analysis [7]; (2). Due to the similar microstructures between the as-cast and T5 gearcases, the tensile performance of the samples taken from each component were similar.…”

Section: Discussionmentioning

confidence: 75%

“…Correspondingly, the thickest section experienced the slowest cooling, reaching only 7.8 • C/s. Such a large difference in cooling rates was described to be one of the causes for the elevated level of residual stress [7] and is expected to result in somewhat dissimilar microstructures and thus mechanical properties. The microstructure of the AH, AR, AS, and AW specimens are shown in Figures 2-5.…”

Section: Microstructurementioning

confidence: 99%

“…This was believed to be caused by the development of high residual stresses during the HPDC process. As a result, the current authors performed a comprehensive residual stress analysis using neutron diffraction on the as-cast and T5 heat-treated transmission gearcases; the results are presented elsewhere [7]. It was observed that the peak magnitude of residual stress reached nearly 120 MPa in the as-condition, accounting for a large magnitude of the material's expected strength.…”

Section: Introductionmentioning

confidence: 96%

See 3 more Smart Citations

The Effects of Heat Treatment on the Microstructure and Tensile Properties of an HPDC Marine Transmission Gearcase

Stroh

Sediako

Hanes

et al. 2021

Metals

Self Cite

View full text Add to dashboard Cite

The drive for continuously improving the performance and increasing the efficiencies of marine transportation has resulted in the development of a new alloy, Mercalloy A362™. This alloy was designed to lighten Mercury Marine’s lower transmission gearcase while also improving the alloy’s recyclability. The new prototype gearcase was subjected to Mercury Marine’s standard service conditions, which resulted in the premature failure of the prototype. A previous study revealed that a large accumulation of unwanted residual stress (~120 MPa) was present in the gearcase following the high pressure die casting process. Fortunately, the T5 heat treatment reduced the magnitude of stress by approximately 50%. However, the effects that the T5 heat treatment had on the microstructure and mechanical properties of the alloy were not discussed. Thus, this research article characterizes the effects that the T5 heat treatment has on the volume fraction and morphology of the intermetallics, as well as the tensile performance of the alloy. It was found that the T5 heat treatment led to only minor increases in the volume fraction of Fe-bearing intermetallics, leading to similar tensile properties in both the as-cast and T5 condition. These results suggest that the T5 heat treatment can alleviate residual stress without significantly altering the mechanical properties of the alloy. The results from the previous stress analysis and the current study were used to optimize the manufacturing process which led to the successful introduction of the gearcase into the competitive marine industry.

show abstract

Section: Discussionmentioning

confidence: 54%

Section: Discussionmentioning

confidence: 75%

Section: Microstructurementioning

confidence: 99%

Section: Introductionmentioning

confidence: 96%

See 2 more Smart Citations

The Effects of Heat Treatment on the Microstructure and Tensile Properties of an HPDC Marine Transmission Gearcase

Stroh

Sediako

Hanes

et al. 2021

Metals

Self Cite

View full text Add to dashboard Cite

show abstract

“…The rapid advancements in manufacturing technologies and the advent of intelligent manufacturing have culminated in heightened expectations for mechanical systems, particularly in terms of efficiency, stability, and durability [16][17][18]. Gear transmission systems, integral to a myriad of machines and devices, are established as exerting a direct impact on the performance and lifespan of the equipment at large [19][20][21].…”

Section: Introductionmentioning

confidence: 99%

Thermodynamic Modelling for Heat Analysis and Prediction in Precision Transmission Systems: A Focus on Gear Operation

Wu,

Han

2023

IJHT

View full text Add to dashboard Cite

In the evolving realm of precision machinery, paramount importance is placed on the efficiency and performance of transmission systems. A central role is played by gears within these systems, with their thermal variations and distributions during operation critically influencing the stability and efficiency of the systems at large. Despite the theoretical support lent by traditional thermodynamic theories and empirical formulas, their prediction accuracy is found lacking, particularly in the face of complex operational environments and dynamic changes. To address this shortfall, this study introduces an advanced thermodynamic model, augmented by the application of a Temporal Convolutional Network (TCN). The integration of these methodologies facilitates a comprehensive thermal analysis and prediction specific to gear operation, aiming to provide enhanced accuracy and real-time thermal data support. This endeavor is vital for not only understanding but also optimizing the thermal behavior of gears in precision transmission systems, ultimately contributing to the advancement of the field.

show abstract

Residual Stress in Automotive Powertrains: Methods and Analyses

Sediako

Stroh

Kianfar

2021

MSF

Self Cite

View full text Add to dashboard Cite

Residual stress is one of the main reasons for failure of automotive cylinder blocks and engine heads. These failures are typically associated with in-service distortion or cracking occurring in engines during operation cycles. The problem becomes more pronounced for engines that are running at elevated operating pressures and temperatures, limiting R&D options in developing and implementing higher-efficiency engines. New aluminum alloys and manufacturing methods have been introduced with varying degree of success, in many cases affected by the stress magnitudes and stress distribution in the component. Therefore, active research is ongoing internationally on finding the most reliable methods of stress analysis as a basis for developing efficient methods for stress mitigation. The current study presents a comparison between two experimental strain measurements techniques: a destructive method that is based on application of strain gauge sensors, and a non-destructive method using neutron diffraction. The results indicate that although the strain gauge method provides an indication of the nature (i.e. compression or tension) of strain within a component, this method should primarily be used for surface measurements and qualitative analyses only. Neutron diffraction remains the superior technique for strain analysis, particularly for engineering components with complex geometries. The results from this study provide the transportation industry with a more comprehensive understanding of the efficacy of utilizing strain gauge sensors, neutron diffraction or finite element modelling for measuring the residual strain in cast components. The results will help manufacturers to develop the next generation of powertrain systems with increased efficiency and improved performance.

show abstract

Residual Stress Characterization for Marine Gear Cases in As-Cast and T5 Heat Treated Conditions with Application of Neutron Diffraction

Cited by 3 publications

References 4 publications

The Effects of Heat Treatment on the Microstructure and Tensile Properties of an HPDC Marine Transmission Gearcase

The Effects of Heat Treatment on the Microstructure and Tensile Properties of an HPDC Marine Transmission Gearcase

Thermodynamic Modelling for Heat Analysis and Prediction in Precision Transmission Systems: A Focus on Gear Operation

Residual Stress in Automotive Powertrains: Methods and Analyses

Contact Info

Product

Resources

About