Investigation of the effect of Laser Shock Peening in Additively Manufactured samples through Bragg Edge Neutron Imaging

Additive manufacturing is a promising and rapidly rising technology in metal processing. However, besides a number of key advantages the constitution of a part through a complex thermo-mechanical process implies also some severe issues with the potential of impacting the quality of products. In laser powder bed fusion (LPBF), the most applied metal additive manufacturing process, the repetitive heating and cooling cycles induce severe strains in the built material, which can have a number of adverse consequences such as deformation, cracking and decreased fatigue life that might lead to severe failure even already during processing. It has been reported recently that the application of laser shock peening (LSP) can counteract efficiently the named issues of LPBF through the introduction of beneficial compressive residual stresses in the surface regions mostly affected by tensile stresses from the manufacturing process. Here we demonstrate how lattice strains implied by LPBF and LSP can efficiently be characterized through diffraction contrast neutron imaging. Despite the spatial resolution need with regards to the significant gradients of the stress distribution and the specific microstructure, which prevent the application of more conventional methods, Bragg edge imaging succeeds to provide essential two-dimensionally spatial resolved strain maps in full field single exposure measurements.

3D Laser Shock Peening – A new method for the 3D control of residual stresses in Selective Laser Melting

Eric Boillat, Jamasp Jhabvala, Nikola Kalentics, Christian Leinenbach, Roland Logé

This paper describes a hybrid additive manufacturing process – 3D Laser Shock Peening (3D LSP), based on the integration of Laser Shock Peening (LSP) with selective laser melting (SLM). The well-known tensile residual stresses (TRS) in the as – built (AB) state of SLM parts in the subsurface region have a detrimental effect on their fatigue life. LSP is a relatively expensive surface post treatment method, known to generate deep CRS into the subsurface of the part, and used for high end applications (e.g. aerospace, nuclear) where fatigue life is crucial. The novel proposed 3D LSP process takes advantage of the possibility to repeatedly interrupt the part manufacturing, with cycles of a few SLM layers. This approach leads to higher and deeper CRS in the subsurface of the produced part, with expected improved fatigue properties. In this paper, 316L stainless steel samples were 3D LSP processed using a decoupled approach, i.e. by moving back and forth the baseplate from an SLM machine to an LSP station. A clear and significant increase in the magnitude and depth of CRS was observed, for all investigated process parameters, when compared to the AB SLM parts, or those traditionally LSP (surface) treated.

Elsevier Sci Ltd2017

Through-thickness performance of adhesive connections between FRP bridge decks and steel main girders

Martin Schollmayer

FRP bridge decks offer several advantages compared with conventional concrete bridge decks, particularly their much lower weight, but also their resistance against corrosion as well as easier installation and maintenance. The poorly conceived methods available for connecting FRP bridge decks with their supporting structures – normally steel girders – nonetheless constitute a disadvantage. Connections involving studs or bolts are not appropriate in this case, since FRP is a very brittle material that offers no ductile properties. Bolted connections usually result in much higher stress concentrations, while adhesive bonding is a more material-adapted connection method since larger surfaces can be linked together, thus ensuring reduced stresses. The bridge system investigated in this thesis consists of a pultruded FRP bridge deck bonded to steel main girders, the bridge's main structural components, which have to transmit the dead and traffic loads to the supports, whereas the bridge deck is spanned in the transverse direction perpendicular to the steel girders. Uplift forces caused by the load-bearing behavior of the bridge deck transverse to the bridge axis lead to through-thickness tensile stresses in the adhesive joint. The main objective of this thesis is the description of the structural behavior in the transverse direction. This includes analysis of the stresses in the adhesive connection as well as determination of the strength of the joints. Analytical and experimental investigations were carried out. It was shown, that the tensile stress distribution in the adhesive joint is non-uniform with high stress concentrations below the FRP deck webs of the cellular deck and above the steel girder web. Alternately inclined deck webs thereby induce significantly higher stresses below the vertical webs. A method for the calculation of the stress state in the adhesive layer is proposed which is validated by numerical and experimental results. The material strength of the connection in terms of a combination of tensile through-thickness and shear stresses is established. The total safety factor of the joint was higher than the safety factor of the FRP deck for bending between the main girders. A possible failure process would not start in the adhesive connection between bridge deck and steel girder which eventually could lead to additional failure of other structural members. The system is redundant. Fatigue loading up to 10 million cycles showed no stiffness degradation. The results of this thesis prove the existence of a good load-bearing behavior under static and fatigue loads of adhesively-bonded joints between pultruded FRP bridge decks and structural steel girders, where the adhesive connection is loaded with uplift forces and moments acting in the bridge deck, in addition to the shear in the connection layer due to composite action. The basis for a design method for adhesively-bonded connections between pultruded FRP bridge decks and steel girders is provided.

EPFL2009

Geometrical and material characterisation of quenched and self-tempered steel reinforcement bars

Eugen Brühwiler, Alain Nussbaumer, Marina Rocha Pinto Portela Nunes

Quenched and self-tempered (QST) steel reinforcement bars (rebars) are manufactured by Thermex or Tempcore processes. Characterization studies of QST rebars are mostly limited to reveal the hardened outer layer and some improved mechanical properties compared to hot-rolled (HR) and cold-worked (CW) rebars. However, investigations on residual stresses and imperfections originating from the manufacturing process as well as stress concentrations arising from the ribbed profile are rarely found in the literature. Surface residual stress may be beneficial or detrimental to the fatigue performance of rebars although they have been studied only on the subsurface of QST rebars. Surface imperfections are zones of stress concentration from where fatigue cracks may initiate. Imperfections are usually identified in the fractured cross section resultant from fatigue tests of rebars. Stress concentrations can also arise from the rib geometry. Although the rib geometric parameters affect the stress concentration factor Kt on rebars, stress concentration analysis are restricted to two-dimensional (2D) finite-element models (FEMs). The study presented herein is part of a further detailed investigation on the fatigue behavior of HR-CW and QST rebars in the very high cycle domain. In the present work, characterization analyses of QST rebars include (1) experimental investigation of surface and subsurface residual stresses on QST rebars by cut compliance and X-ray diffraction techniques (residual stresses from both techniques are discussed); (2) identification of surface imperfections by scanning electron microscopy (SEM) analysis; and (3) three-dimensional (3D) finite-element analysis of stress concentrations on the ribbed profile. The influence of the rib geometry such as radius, width, height, and inclination as well as the rebar diameter on Kt values are analyzed. The critical zones are determined along the ribs. (C) 2016 American Society of Civil Engineers.