Review: Residual Stress Measurement Methods, Reasons and Prevention Studies in Aluminium Cast Alloys

Abstract

This study investigates the causes, measurement methods, and prevention strategies of residual stresses occurring in cast aluminum alloys during the manufacturing process. Residual stresses are elastic internal stresses that form in materials without any external load, typically due to processes like heat treatment, machining, or welding. These stresses directly affect the fatigue life, mechanical performance, and dimensional accuracy of components. In particular, sudden temperature changes during solution treatment and quenching in T6 heat treatment processes can lead to significant residual stresses. The study provides a detailed comparison of destructive methods (e.g., hole-drilling, ring-core, contour methods), non-destructive techniques (e.g., X-ray diffraction, ultrasonic testing, neutron diffraction), and analytical approaches using finite element modeling. The strengths and limitations of each method are discussed. In terms of fatigue performance, tensile residual stresses can be detrimental, while compressive stresses can enhance service life. Thus, accurate measurement and effective control of these stresses are crucial. Techniques such as stress relief annealing, low-temperature aging, and mechanical surface treatments are highlighted as effective in reducing residual stress. In conclusion, managing residual stresses carefully is essential for producing more durable and reliable engineering components.

Keywords

• Cast Aluminum Alloys
• Residual Stress
• Destructive and Non-Destructive Measurement Methods

İnceleme: Döküm Alüminyum Alaşımlarında Kalıntı Gerilme Ölçüm Yöntemleri, Nedenleri ve Önleme Çalışmaları

Öz

Bu çalışma, döküm alüminyum alaşımlarında üretim sürecinde ortaya çıkan kalıntı gerilmelerin nedenlerini, ölçüm yöntemlerini ve önleme stratejilerini incelemektedir. Kalıntı gerilmeler; ısıl işlem, talaşlı imalat, kaynak gibi işlemlerden sonra, dış yük olmadan malzeme içinde oluşan elastik gerilmelerdir. Bu gerilmeler, parçanın yorulma ömrünü, mekanik performansını ve boyutsal doğruluğunu doğrudan etkiler. Özellikle T6 gibi ısıl işlem süreçlerinde, su verme sırasında meydana gelen ani sıcaklık değişimleri ciddi kalıntı gerilmeler yaratabilir. Çalışmada delik delme, halka çekirdek ve kontur gibi tahribatlı; X-ışını kırınımı, ultrasonik ve nötron kırınımı gibi tahribatsız yöntemler detaylı şekilde incelenmiş, bunların avantaj ve dezavantajları karşılaştırılmıştır. Ayrıca, sonlu elemanlar analizleriyle yapılan analitik ölçüm yöntemlerine de yer verilmiştir. Yorulma ömrü açısından, çeki kalıntı gerilmeleri zararlı olurken, bası gerilmeleri ömrü artırabilir. Bu nedenle kalıntı gerilmelerin ölçümü kadar kontrolü de önemlidir. Gerilme giderme tavlaması, düşük sıcaklıkta yaşlandırma ve yüzey işlemleri gibi yöntemlerle bu gerilmeler azaltılabilir. Sonuç olarak, kalıntı gerilmelerin dikkatli yönetimi, daha dayanıklı ve güvenilir mühendislik parçaları üretimini mümkün kılar.

Anahtar Kelimeler

• Döküm Alüminyum Alaşımları
• Kalıntı Gerilme
• Tahribatlı ve Tahribatsız Ölçüm Yöntemleri.

Kaynakça

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