Neutron diffraction measurements of residual stresses in friction stir welding: A review

Abstract Significant amounts of residual stresses are often generated during welding and result in critical degradation of the structural integrity and performance of components. Neutron diffraction has become a well established technique for the determination of residual stresses in welds because of the unique deep penetration, three‐dimensional mapping capability, and volume averaged bulk measurements characteristic of the scattering neutron beam. Friction stir welding has gained prominence in recent years. The authors reviewed a number of neutron diffraction measurements of residual stresses in friction stir welds and highlighted examples addressing how the microstructures and residual stresses are correlated with each other. An example of in situ neutron diffraction measurement result shows the evolution of the residual stresses during welding.

[1]  Aaas News,et al.  Book Reviews , 1893, Buffalo Medical and Surgical Journal.

[2]  A. Krawitz,et al.  Introduction to Diffraction in Materials Science and Engineering , 2001 .

[3]  富村 寿夫,et al.  Friction Stir Welding(摩擦撹拌接合)法の熱工学的研究 , 2005 .

[4]  Yutaka S. Sato,et al.  Effect of micro-texture on fracture location in friction stir weld of Mg alloy AZ61 during tensile test , 2003 .

[5]  S. David,et al.  Residual stress mapping in multipass ferritic steel weld , 1993 .

[6]  S. Jung,et al.  The joint properties of copper by friction stir welding , 2004 .

[7]  K. An,et al.  In situ neutron diffraction measurements of temperature and stresses during friction stir welding of 6061-T6 aluminium alloy , 2007 .

[8]  H. Bhadeshia,et al.  Residual stress. Part 2 – Nature and origins , 2001 .

[9]  P. Withers,et al.  Residual stress and its role in failure , 2007 .

[10]  P. J. Webster,et al.  Synchrotron X-ray residual strain scanning of a friction stir weld , 2001 .

[11]  C. Windsor,et al.  Measurement of internal stress within bulk materials using neutron diffraction , 1981 .

[12]  J. Cohen,et al.  Residual Stress: Measurement by Diffraction and Interpretation , 1987 .

[13]  Rajiv S. Mishra,et al.  Microstructural investigation of friction stir welded 7050-T651 aluminium , 2003 .

[14]  Philip J. Withers,et al.  The variation of the unstrained lattice parameter in an AA7010 friction stir weld , 2007 .

[15]  T. Gnäupel-Herold,et al.  Residual stress measurements in a thick, dissimilar aluminum alloy friction stir weld , 2006 .

[16]  A. Reynolds,et al.  Relationships between weld parameters, hardness distribution and temperature history in alloy 7050 friction stir welds , 2005 .

[17]  Zhili Feng,et al.  Feasibility of Thermal Strain Measurements during Quasi-Steady State Using Neutron Diffraction , 2006 .

[18]  R. Winholtz,et al.  Use of position-dependent stress-free standards for diffraction stress measurements , 1994 .

[19]  Zhili Feng,et al.  Modelling of residual stresses and property distributions in friction stir welds of aluminium alloy 6061-T6 , 2007 .

[20]  P. Liaw,et al.  Texture variation and its influence on the tensile behavior of a friction-stir processed magnesium alloy , 2006 .

[21]  S. L. Semiatin,et al.  Continuous dynamic recrystallization during friction stir welding of high strength aluminum alloys , 2000 .

[22]  G. G. Stokes "J." , 1890, The New Yale Book of Quotations.

[23]  K. Masubuchi Analysis of Welded Structures , 1980 .

[24]  W. Woo,et al.  Microstructure, texture and residual stress in a friction-stir-processed AZ31B magnesium alloy , 2008 .

[25]  S. David,et al.  Deconvoluting the influences of heat and plastic deformation on internal strains generated by friction stir processing , 2005 .

[26]  M. Preuss,et al.  Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminium AA5083 friction stir welds , 2003 .

[27]  W. Woo,et al.  Influence of the Tool Pin and Shoulder on Microstructure and Natural Aging Kinetics in a Friction-Stir-Processed 6061–T6 Aluminum Alloy , 2007 .

[28]  Murray W. Mahoney,et al.  Effects of friction stir welding on microstructure of 7075 aluminum , 1997 .

[29]  Øystein Grong,et al.  A process model for friction stir welding of age hardening aluminum alloys , 2001 .

[30]  K. An,et al.  IN-SITU NEUTRON DIFFRACTION MEASUREMENT OF TRANSIENT TEMPERATURE AND STRESS FIELDS IN A THIN PLATE , 2006 .

[31]  D. Harris Pulsed Neutron Scattering , 1986 .

[32]  Y. Carlan,et al.  Study of PM2000 microstructure evolution following FSW process , 2009 .

[33]  Philip J. Withers,et al.  Mapping residual and internal stress in materials by neutron diffraction , 2007 .

[34]  M. Daymond,et al.  Lattice strain evolution during uniaxial tensile loading of stainless steel , 1999 .

[35]  Thomas J. Lienert,et al.  Three-dimensional heat and material flow during friction stir welding of mild steel , 2007 .

[36]  Stewart Williams,et al.  Residual stresses in friction stir welded Al sheets , 2002 .

[37]  M. W. Mahoney,et al.  Properties of friction-stir-welded 7075 T651 aluminum , 1998 .

[38]  P. Withers,et al.  Comparison of three different techniques for measuring the residual stresses in an electron beam-welded plate of WASPALOY , 1999 .

[39]  Philip J. Withers,et al.  Residual stress engineering in friction stir welds by roller tensioning , 2009 .

[40]  P. Liaw,et al.  Angular distortion and through-thickness residual stress distribution in the friction-stir processed 6061-T6 aluminum alloy , 2006 .

[41]  R. Mishraa,et al.  Friction Stir Welding And Processing , 2005 .

[42]  D. Lloyd,et al.  Modeling of precipitation hardening for the naturally aged Al-Mg-Si-Cu alloy AA6111 , 2003 .

[43]  W. Marsden I and J , 2012 .

[44]  Zhili Feng,et al.  Texture analysis of a friction stir processed 6061-T6 aluminum alloy using neutron diffraction , 2006 .

[45]  M. J. Jirinec,et al.  Experimental determination of the residual stresses in a spiral weld overlay tube , 1997 .

[46]  Jean-Eric Masse,et al.  Friction stir welding of AZ31 magnesium alloy rolled sheets: Influence of processing parameters , 2009 .

[47]  Zhili Feng Processes and mechanisms of welding residual stress and distortion , 2005 .

[48]  Donald E. Boyce,et al.  A multiscale methodology for deformation modeling applied to friction stir welded steel , 2006 .

[49]  H. Suzuki,et al.  Stress measurements in welds : Problem areas , 2006 .

[50]  W. Woo,et al.  Neutron diffraction measurements of time-dependent residual stresses generated by severe thermomechanical deformation , 2009 .

[51]  U. Lienert,et al.  Residual stress distribution in steel butt welds measured using neutron and synchrotron diffraction , 2009, Journal of physics. Condensed matter : an Institute of Physics journal.

[52]  K. Masubuchi CHAPTER 2 – Heat Flow in Weldments , 1980 .

[53]  Yuh J. Chao,et al.  Numerical simulation of transient temperature and residual stresses in friction stir welding of 304L stainless steel , 2004 .

[54]  Lawrence E Murr,et al.  A TEM study of precipitation and related microstructures in friction-stir-welded 6061 aluminium , 1998 .

[55]  T. J. Lienert,et al.  Improved weldability diagram for pulsed laser welded austenitic stainless steels , 2003 .

[56]  E. D. Nicholas,et al.  Feasibility of friction stir welding steel , 1999 .

[57]  T. Mason,et al.  In situ generation of intergranular strains in an Al7050 alloy , 1998 .

[58]  A. Steuwer,et al.  Investigation of reference samples for residual strain measurements in a welded specimen by neutron and synchrotron X-ray diffraction , 2006 .

[59]  Mark R. Daymond,et al.  Use of Rietveld refinement for elastic macrostrain determination and for evaluation of plastic strain history from diffraction spectra , 1997 .

[60]  H. Rietveld A profile refinement method for nuclear and magnetic structures , 1969 .

[61]  Lawrence E Murr,et al.  Heat input and temperature distribution in friction stir welding , 1998 .

[62]  Philip J. Withers,et al.  Dissimilar friction stir welds in AA5083-AA6082: The effect of process parameters on residual stress , 2006 .

[63]  P. J. Webster,et al.  Neutron diffraction measurements of residual stress and plastic deformation in an aluminium alloy weld , 1988 .

[64]  Robert L. Taylor,et al.  Microstructural studies of friction stir welds in 2024-T3 aluminum , 2002 .

[65]  Antonio J. Ramirez,et al.  Microstructural Evolution in Ti-6Al-4V Friction Stir Welds , 2003 .

[66]  Philip J. Withers,et al.  Global mechanical tensioning for the management of residual stresses in welds , 2008 .

[67]  Andrew G. Glen,et al.  APPL , 2001 .

[68]  R. Fonda,et al.  Development of grain structure during friction stir welding , 2004 .

[69]  D. Brown,et al.  Residual stress measurements in a zircaloy-4 weld by neutron diffraction , 2004 .

[70]  Xinjin Cao,et al.  Microstructure and tensile properties of friction stir welded AZ31B magnesium alloy , 2008 .

[71]  V. Linton,et al.  Influence of time on residual stresses in friction stir welds in agehardenable 7xxx aluminium alloys , 2008 .

[72]  R. Steel,et al.  In situ thermal studies and post-weld mechanical properties of friction stir welds in age hardenable aluminium alloys , 2003 .

[73]  C. Dalle Donne,et al.  Investigations on Residual Stresses in Friction Stir Welds , 2001 .

[74]  P. Withers,et al.  Introduction to the Characterization of Residual Stress by Neutron Diffraction , 2005 .

[75]  P. Prangnell,et al.  Geometry Effects when Controlling Residual Stresses in Friction Stir Welds by Mechanical Tensioning , 2006 .

[76]  W. M. Thomas,et al.  Friction stir process welds aluminium alloys : The process produces low-distortion, high-quality, low-cost welds on aluminium , 1996 .

[77]  Xun-li Wang,et al.  Diffraction Peak Displacement in Residual Stress Samples Due to Partial Burial of the Sampling Volume , 1997 .

[78]  Michael A. Sutton,et al.  A Study of Residual Stresses and Microstructure in 2024-T3 Aluminum Friction Stir Butt Welds , 2002 .

[79]  Massimo Rogante,et al.  Determination of residual stresses in materials and industrial components by neutron diffraction , 1999 .

[80]  Rajiv S. Mishra,et al.  Superplastic deformation behaviour of friction stir processed 7075Al alloy , 2002 .

[81]  Hiroyuki Kokawa,et al.  Precipitation sequence in friction stir weld of 6063 aluminum during aging , 1999 .

[82]  Anthony P. Reynolds,et al.  Structure, Properties, and Residual Stress of 304L Stainless Steel Friction Stir Welds , 2003 .