Quenching and Cold-Work Residual Stresses in Aluminum Hand Forgings : Contour Method Measurement and FEM Prediction

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The cold-compression stress relief process used to reduce the quench-induced stresses in high-strength aerospace aluminum alloy forgings does not fully relieve the stresses. This study measured and predicted the residual stress in 7050-T74 (solution heat treated, quenched, and artificially overaged) and 7050-T7452 (cold compressed prior to aging) hand forgings. The manufacturing process was simulated by finite element analysis. First, a thermal analysis simulated the quench using appropriate thermal boundary conditions and temperature dependent material properties. Second, a structural analysis used the thermal history and a temperature and strain-rate dependent constitutive model to predict the stresses after quenching. Third, the structural ... continued below

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7 p.

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Prime, M. B. (Michael B.); Newborn, M. A. (Mark A.) & Balog, J. A. (John A.) January 1, 2003.

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Description

The cold-compression stress relief process used to reduce the quench-induced stresses in high-strength aerospace aluminum alloy forgings does not fully relieve the stresses. This study measured and predicted the residual stress in 7050-T74 (solution heat treated, quenched, and artificially overaged) and 7050-T7452 (cold compressed prior to aging) hand forgings. The manufacturing process was simulated by finite element analysis. First, a thermal analysis simulated the quench using appropriate thermal boundary conditions and temperature dependent material properties. Second, a structural analysis used the thermal history and a temperature and strain-rate dependent constitutive model to predict the stresses after quenching. Third, the structural analysis was continued to simulate the multiple cold compressions of the stress relief process. Experimentally, the residual stresses in the forgings were mapped using the contour method, which involved cutting the forgings using wire EDM and then measuring the contour of the cut surface using a CMM. Multiple cuts were used to map different stress components. The results show a spatially periodic variation of stresses that results from the periodic nature of the cold work stress relief process. The results compare favorably with the finite element prediction of the stresses.

Physical Description

7 p.

Source

  • "Submitted to Materials Science Forum, Vols. 426-432, pp. 435-440, 2003. (proc. of THERMEC'2003: Processing&Manufacturing of Advanced Materials, July 7-11, 2003, LeganÅ¡, Madrid, Spain.)

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  • Report No.: LA-UR-03-0585
  • Report No.: LA-UR-03-585
  • Grant Number: none
  • Office of Scientific & Technical Information Report Number: 976531
  • Archival Resource Key: ark:/67531/metadc929170

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

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  • January 1, 2003

Added to The UNT Digital Library

  • Nov. 13, 2016, 7:26 p.m.

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  • Dec. 12, 2016, 4:35 p.m.

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Prime, M. B. (Michael B.); Newborn, M. A. (Mark A.) & Balog, J. A. (John A.). Quenching and Cold-Work Residual Stresses in Aluminum Hand Forgings : Contour Method Measurement and FEM Prediction, article, January 1, 2003; United States. (digital.library.unt.edu/ark:/67531/metadc929170/: accessed September 23, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.