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The measurement and control of residual stresses are crucial to the structural safety of high-speed trains. The critical refraction longitudinal wave method is extensively employed for the residual stress measurement, and the correction of the influencing factors is the key to the detection accuracy. However, the existing methods mostly give purely mathematical expressions which are only applicable to their studied materials. Hence, this paper proposes the specific influence factor correction method to enhance the applicability and accuracy, and the 5083 aluminum alloy welded component is utilized for testing. Subsequently, the stress coefficient K and the compensation acoustic time under the influence of internal factors are obtained by employing the proposed method, combined with the simulation to determine the focused detection zone, the hole-drilling and X-ray methods are utilized for comparisons, and the results indicate that the test data have a good coincidence. Meanwhile, the detection errors of each zone before and after the correction are analyzed. Moreover, combined with the experimental verification, it is found that the penetration depth of a critical refraction longitudinal wave approaches its one wavelength; the corresponding study is conducted with this characteristic and concludes that in the weld zone, the longitudinal residual stresses are mainly concentrated on the surface of the measured material. Finally, the above results indicate that the proposed method can provide more accurate measurements for engineering applications.
The measurement and control of residual stresses are crucial to the structural safety of high-speed trains. The critical refraction longitudinal wave method is extensively employed for the residual stress measurement, and the correction of the influencing factors is the key to the detection accuracy. However, the existing methods mostly give purely mathematical expressions which are only applicable to their studied materials. Hence, this paper proposes the specific influence factor correction method to enhance the applicability and accuracy, and the 5083 aluminum alloy welded component is utilized for testing. Subsequently, the stress coefficient K and the compensation acoustic time under the influence of internal factors are obtained by employing the proposed method, combined with the simulation to determine the focused detection zone, the hole-drilling and X-ray methods are utilized for comparisons, and the results indicate that the test data have a good coincidence. Meanwhile, the detection errors of each zone before and after the correction are analyzed. Moreover, combined with the experimental verification, it is found that the penetration depth of a critical refraction longitudinal wave approaches its one wavelength; the corresponding study is conducted with this characteristic and concludes that in the weld zone, the longitudinal residual stresses are mainly concentrated on the surface of the measured material. Finally, the above results indicate that the proposed method can provide more accurate measurements for engineering applications.
Ultrasonic surface wave have been implemented to measure or predict the existing stress on material. Surface wave velocity shows linearly increase with stress applied in material. However, various applications were coated their surfaces with high corrode resistance material for example paint or aluminum thermal sprays. It may cause the change of the velocity of surface wave and lead to miss prediction. This paper presents the effect of material coating on surface wave velocity and its attenuations. Paint and Aluminum thermal spray coated on low carbon steel graded S420 (EN 10025 Standard) in the range of 100-500 micron. Through transmission ultrasonic surface wave was applied to measure the velocities change. Their frequencies are 2.25 and 5 MHz respectively. It was found that coating thickness show effect on sound velocity and sound wave attenuation. The benefit is to know the effect of coating and to approve the accuracy of stress measurement by ultrasonic wave.
Welding, which is a largely used process in the mechanical manufacturing, well known to induce high-level residual stresses. The level of residual stresses is of great importance for the lifetime of welded components used in mechanical engineering industry. The use of the ultrasonic method for the evaluation of the residual stresses is based on the acoustoelastic effect, which refers to the change in velocity of the acoustic waves propagating in a strained solid. In the case of welding, the microstructure modifications observed in the heat affected zone (HAZ) and the melted zone (MZ) also induce variations of the velocity of the acoustic waves. The superposition of the two effects, stresses and microstructure, results in over-estimating the levels of stresses. This work which was completed in collaboration with CETIM is a contribution to this problem. The experimental study was carried out on P460HLE and P265 steels welded sheets. The results obtained by the ultrasonic Lcr wave technique were compared with those obtained by the hole drilling technique. This work confirms the possibility of evaluating the residual stresses induced by welding using the ultrasonic method.
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