Search

Residual stress is an important factor that affects the properties of cold spray coatings. The study performed 2D single-, 3D single-, and 3D multiple-particle finite element simulations based on the Eulerian method, and hole drilling measurements to study residual stress in cold-sprayed copper coatings. The study examined how the basic modeling parameters affect residual stress in the 2D system. It found that the mesh size, substrate dimension, and simulation duration change the residual stress; while material failure does not have much effect because failure is localized. It also found that thermal softening, which occurs when the initial temperature and/or plastic deformation increase, helps to reduce the residual stress. In addition, the residual stress along the axisymmetric axis of the particle changes from being compressive at first to being compressive-tensile-compressive along the through-depth thickness direction with the interfacial stress being tensile that mainly originates from friction shear of the interfacial layers. For the 3D single-particle simulations, the average residual stress to the through-depth thickness shows tension to compression transition and is similar to the 2D cases. For the 3D multiple-particle simulations, the residual stresses in the coatings/substrate are all compressive because of the repeated and strong impact of the particles, which agree with the experimental measurements. The study also found that the compressive stresses decrease when the coating thickness increases because of more plastic deformation-induced thermal softening. This paper clarifies the effects of Eulerian-based finite element parameters on simulating residual stress in cold spray and will serve as a valuable reference for future studies. [ABSTRACT FROM AUTHOR]

This study focuses on the experimental verification of residual stress (RS) in a 3D-printed braking pedal using the Powder Bed Fusion (PBF) method with SS316L material. The RS was measured at two representative locations using the hole drilling method (HDM) and the dividing method, which are semi-destructive and destructive methods of RS measurement, respectively. The finite element method (FEM) was used with Ansys Workbench 2020R2 and Simufact Additive 2021 software to determine the magnitude of RS. The results provide insights into how RS is incorporated into metal 3D-printed components and the available tools for predicting RS. This information is essential for experts to improve the accuracy and functionality of SLM parts when post-subtractive or additive manufacturing processes are used. Overall, this study contributes to the advancement of knowledge on the effects of RS on 3D-printed metal components, which can inform future research and development in this area. [ABSTRACT FROM AUTHOR]

Plasma spraying is commonly used to deposit thick metallic coatings. The high deposition temperature and complex interaction of the process parameters result in tensile residual stresses in thick metallic layers. Tensile residual stresses are widely known to affect the integrity of metallic coatings. The present study uses a combination of hole drilling and micro-indentation techniques to evaluate the residual stress developed in Ni-based metallic coatings deposited on stainless steel substrate using a direct current plasma spray torch. The metallic coating samples are first characterized by microscopy, surface roughness measurement, micro-indentation, and scratch tests before through-thickness residual strain measurement via the incremental hole-drilling method. The residual stress in the metallic coating layers is evaluated from the incremental strain measurements and micro-indentation curves. The studies show that the residual stress can be reliably predicted using the combination of hole drilling and micro-indentation measurements. It is found that tensile residual stresses are developed across the depth of both NiCrAl and Ni–20Al coatings. The variation of the tensile residual stresses across the depth is nonlinear and almost equibiaxial. The residual stress strongly influences the adhesion strength of the thick metallic coating layers.

Background: Relaxation methods determine residual stresses by measuring the deformations produced by incremental removal of a subdomain of the specimen. Measured strains at any given increment, determined by the cumulative effect of the relieved stresses, appear as an integral equation, which must be inverted to obtain residual stresses. In practice, stress distributions are discretized by a finite-dimensional basis, to transform the integral equations into a linear system of equations, which is often ill-conditioned. Objective: This article demonstrates that the problem is actually ill-posed and comes with an inherent bias-variance tradeoff. Methods: The hole drilling method is used as an example application, and the practical effects of ill-posedness are illustrated. Results: Traditional regularization of the solution by limiting the resolution of the discretization reduces solution variance (noise) at the expense of increased bias and often results in the ultimately harmful practice of taking fewer data points. A careful analysis including the alternate Tikhonov regularization approach shows that the highest number of measurements should always be taken to reduce the variance for a given regularization scheme. Unfortunately, the variability of a regularized solution cannot be used to build a valid confidence interval, since an unknown bias term is always present in the true overall error. Conclusions: The mathematical theory of ill-posed problems provides tools to manage the bias-variance tradeoff on a reasonable statistical basis, especially when the statistical properties of measurement errors are known. In the long run, physical arguments that provide constraints on the true solution would be of utmost importance, as they could regularize the problem without introducing an otherwise unknown bias. Constraining the minimum length scale to some physically meaningful value is one promising possibility. [ABSTRACT FROM AUTHOR]

The features of the methodological approach and software implementation are outlined for an experimental–computational method for determining significantly inhomogeneous (up to discontinuous) residual stress fields in flat parts with the use of a drilling method based on mathematical processing of displacement fields registered using digital optical methods. The technique is based on the general solution of the plane problem of elasticity theory obtained by N.I. Muskhelishvili for a plate of unlimited dimensions with a circular hole, the contour of which is affected by arbitrary normal and tangential loads. An algorithm and software for mathematical experimental data processing in the form of tangential displacement fields that occur after drilling a hole serving as an indicator of residual stresses in order to obtain the distribution of the initial residual stress fields have been developed. Based on the numerical experiment, requirements for the accuracy and amount of experimental information providing high accuracy in determining the residual stresses are established. [ABSTRACT FROM AUTHOR]

Simulation model accuracy of quench induced residual stress in wrought magnesium alloy Mg‒Gd–Y–Zr–Ag–Er is tested by applying both isotropic and anisotropic criteria models in residual stress FEM simulation. Both hexagonal close-packed (HCP) lattice structure and asymmetry are considered in the manufacturing process. The distributions of residual stress in isotropic and anisotropic criteria models differ both in distribution and in value, which is due to stress-strain nonuniformity in extrusion direction (ED) and long transverse direction (LTD). Comparing the experimental and predicted errors of the two models, the anisotropic model improves the prediction accuracy by 8.3% in ED and 4.8% in LTD. Residual stress in LTD is always larger than that in ED by the XRD method, and the average deviation between the XRD method and the hole-drilling method is reduced through electropolishing. [ABSTRACT FROM AUTHOR]

Surface treatment techniques such as laser shock peening (LSP) represent a consolidated strategy to induce the presence of compressive residual stresses beneath the surface of various metallic alloys. However, surface roughening caused by the process must be monitored, since it may negatively affect fatigue life, resulting in earlier crack initiation. For this reason, the interplay between the key factors affecting both the surface roughness and the development of residual stresses was experimentally examined. The surface roughness was assessed through the determination of roughness average and roughness total height values, whereas residual stresses were assessed using the x-ray diffraction technique and hole drilling method to obtain information about the stress status of the components. Higher values of laser power density resulted in higher values of maximum compressive stress both along scanning and stepping direction and residual stresses remained approximately constant up to a depth of about 0.7-0.8 mm beneath the treated surface. No substantial difference was observed between the residual stress components in the two main LSP directions. Moreover, it was found that the approach to use lower values of nominal power density together with a higher number of layers allows obtaining the same stress condition determined by the use of the highest value of nominal power density but a significantly lower impact on the surface roughness. [ABSTRACT FROM AUTHOR]

Residual stress measurement is of utmost importance for the safety and reliability of engineering components and has been an active area of scientific research. Relaxation techniques such as hole drilling, slitting and ring core method are widely applied semi destructive techniques for residual stress measurements in polymer composites. This article reviews the recent literature on the measurement of residual stress in polymer composite by employing the above-mentioned relaxation techniques. This article summarizes the categories of residual stresses, causes of formation, techniques of measurements and also briefly outlines the chronological developments of the Hole drilling and slitting method. The article also provides a comparative summary of these relaxation methods.

This study focuses on the experimental verification of residual stress (RS) in a 3D-printed braking pedal using the Powder Bed Fusion (PBF) method with SS316L material. The RS was measured at two representative locations using the hole drilling method (HDM) and the dividing method, which are semi-destructive and destructive methods of RS measurement, respectively. The finite element method (FEM) was used with Ansys Workbench 2020R2 and Simufact Additive 2021 software to determine the magnitude of RS. The results provide insights into how RS is incorporated into metal 3D-printed components and the available tools for predicting RS. This information is essential for experts to improve the accuracy and functionality of SLM parts when post-subtractive or additive manufacturing processes are used. Overall, this study contributes to the advancement of knowledge on the effects of RS on 3D-printed metal components, which can inform future research and development in this area.

Determination and knowledge of the stress-strain state of critical structures and machine parts allows one to take preventive actions. A new approach is proposed to using the laser interferometry method designed to assess residual welding stresses in metal structures. The distinctive feature of this approach is the use of two lasers with different wavelengths simultaneously allowing one to increase the accuracy of the information received. This results in a reduction in the measurement error due to the discreteness of the measurement of residual stresses when counting interference fringes. Improving the measurement accuracy is especially important for cases where the level of residual stresses has relatively small values, for example, post-welding stresses of "light" alloys, shot blasting, and laser surface hardening. [ABSTRACT FROM AUTHOR]

Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters. [ABSTRACT FROM AUTHOR]

An important trend in recent ships and offshore structures is that they require high strength as well as light weight. Due to this trend, various materials are being used to replace existing carbon steel, with aluminum alloys being used frequently. In particular, this trend is conspicuous in outfitting rather than in traditional structural strength members. As a typical example, the use of aluminum alloys is increasing in helideck structures and handrails, which are tertiary components. In order to make the example structures above, welding is absolutely necessary. There are various welding methods used for aluminum alloy, with gas metal arc welding (GMAW) the most widely used. It is very important to be able to simulate welding and to predict various physical quantities of this welding technique in the production of aluminum alloy structures. In particular, welding-induced residual stresses are always generated in a structure that has been welded, and can greatly influence structural stability. Therefore, this paper proposes a method to simulate the welding phenomenon using a precise welding heat source for various aluminum alloys. Additionally, the validity of the proposed finite element (FE) analysis method is verified by measuring the residual stress of the representative aluminum alloy. [ABSTRACT FROM AUTHOR]

Residual stresses significantly affect the overall lifetime of constructions. The main disadvantage of residual stresses is that their effect and magnitude is not evident at first sight and can only be reliably determined using experimental methods. The experiment aimed to find out how much the cladding technology affects the residual stresses within the renovation of high pressure die casting molds. A total of four samples were prepared by different cladding techniques and with varying thicknesses of the result layer. The samples were then annealed and mechanically treated. Finally, the hole drilling method was applied to determine the residual stresses in the samples. The results point to more significant differences in the levels of residual stresses, which were determined in the subsurface layers. [ABSTRACT FROM AUTHOR]

A method of experimental and computational analysis of residual stress fields in flat parts based on mathematical processing of deformation response fields arising during drilling in the investigated area of a circular hole is proposed. In contrast to the classical method of drilling a hole, it is considered that there is a substantially inhomogeneous residual stress field in the area of the hole. For calculation of the residual stresses, a general solution obtained by N.I. Muskhelishvili for a two-dimensional problem of the theory of elasticity for a plate of unlimited dimensions with a circular hole, the contour of which is subjected to arbitrary normal and tangential loads, is used. The requirements for the accuracy and volume of the experimental data providing high accuracy of the results are established based on the numerical analysis (FEM) and experimental investigation using the flat optical model of the problem of a high-gradient (piecewise homogeneous) residual stress field. [ABSTRACT FROM AUTHOR]

Among the various Additive Manufacturing (AM) technologies available for metal part production, powder bed processes are the most promising for industrial mass production. However, one obstacle to the widespread adoption of AM technologies is the effect of the residual stress state on the integrity and lifetime of parts. The residual stress state is influenced to a great extent by the geometry and orientation of the part, and such conditions as the distance of the part regions from the building platform or geometrical constraints may change the stress values and distribution. This work describes an experimental activity that has made it possible to draw the trend of the residual stress beneath the surfaces of thin samples produced in AISi10Mg alloy through a Laser Powder Bed Fusion (L-PBF) process, in order to evaluate how stresses are altered by different geometrical constraints.

This study examined the residual stresses on the surface and in the interior of a deep-drawn cup made from a 1180-MPa class ultra-high strength steel sheet. A high residual stress causes a delayed material fracture, and an accurate evaluation of residual stress reduces failure risks. Nevertheless, the residual stress in the vicinity of the scratch marks, induced by galling in the stamping process, remains unclear. This study accordingly presented X-ray diffraction measurements of the considerable residual compressive stress associated with the scratch marks. Measurements obtained using the hole drilling method revealed a previously unknown high residual tensile stress (exceeding 1000 MPa) in the interior at the scratch mark locations, corresponding to a 0.1-mm-thick compressive zone. These measurements were then compared with the results of a finite element (FE) simulation of the deep drawing process performed without the formation of the scratch marks; the simulated residual stress in the scratch mark region considerably deviated from the measurements. A compressive stress of approximately 1000 MPa was therefore imposed on the local surface area to account for the formation of the scratch marks. The prediction of the actual residual stress on the surface and in the interior of the scratch mark region was then discussed. A simple surface stress modification technique for scratch mark prediction was realized from the comparison between the measured and FE simulation results. The stored friction work, modified by the equivalent plastic strain induced by deep drawing, could be adopted to accurately predict the location of the scratch mark region. [ABSTRACT FROM AUTHOR]

Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters.

The present work introduces a novel methodology to analyse non-uniform residual stresses in composite materials. For robust determination of stresses in complex structures made of different layers, it is first necessary to prove that residual stress analysis in a single layer structure can reliably be accomplished. In present work a unidirectional carbon fibre reinforced epoxy is investigated. For residual stress determination, the integral incremental hole drilling method is used. It is revealed that the standard evaluation formalism for non-uniform stress analysis in isotropic structures is not applicable. A novel methodology based on the formalism for uniform stress analysis in orthotropic materials is introduced and applied for determining non-uniform residual stress states in depth. For calibration, a known load is induced by bending of samples. By comparing data obtained with the known bending stresses, the reliability of measurements is analysed and the novel formalism introduced is validated.

An important trend in recent ships and offshore structures is that they require high strength as well as light weight. Due to this trend, various materials are being used to replace existing carbon steel, with aluminum alloys being used frequently. In particular, this trend is conspicuous in outfitting rather than in traditional structural strength members. As a typical example, the use of aluminum alloys is increasing in helideck structures and handrails, which are tertiary components. In order to make the example structures above, welding is absolutely necessary. There are various welding methods used for aluminum alloy, with gas metal arc welding (GMAW) the most widely used. It is very important to be able to simulate welding and to predict various physical quantities of this welding technique in the production of aluminum alloy structures. In particular, welding-induced residual stresses are always generated in a structure that has been welded, and can greatly influence structural stability. Therefore, this paper proposes a method to simulate the welding phenomenon using a precise welding heat source for various aluminum alloys. Additionally, the validity of the proposed finite element (FE) analysis method is verified by measuring the residual stress of the representative aluminum alloy.

In this research work, a finite element model is developed to predict the temperature field and residual stress during plasma arc welding of thin Ti-6Al-4V sheets. Dhinakaran’s heat source model which is based on Parabolic Gaussian distribution is used to predict the temperature field and Anand’s model is used to predict the residual stress. Numerical simulation is performed using ANSYS®. Heat transfer analysis is carried out primarily and the temperature field is given as the input for structural analysis. The concept of APDL programming is used to implement the governing equations. Experimental work has also been conducted to validate the predicted data. Hole Drilling Method (HDM), a semi destructive method and XRD analysis is used to measure the residual stress on the welded specimen. A good agreement is found between the predicted values and measured values.

Residual stresses significantly affect the overall lifetime of constructions. The main disadvantage of residual stresses is that their effect and magnitude is not evident at first sight and can only be reliably determined using experimental methods. The experiment aimed to find out how much the cladding technology affects the residual stresses within the renovation of high pressure die casting molds. A total of four samples were prepared by different cladding techniques and with varying thicknesses of the result layer. The samples were then annealed and mechanically treated. Finally, the hole drilling method was applied to determine the residual stresses in the samples. The results point to more significant differences in the levels of residual stresses, which were determined in the subsurface layers.

Ti-48Al-2Cr-2Nb (Ti-48-2-2) is an intermetallic alloy belonging to a family of gamma-TiAl intermetallic alloys that are attracting significant attention. Electron Beam Melting (EBM) process is today the only manufacturing process that allows effective production of parts made by these kinds of alloys. Proper process control avoids high temperatures in the surrounding areas that may generate significant residual stresses that could cause micro-cracks. In this paper, an investigation on the residual stress state on Ti-48-2-2 parts is carried out using the hole drilling method. In particular, the influence of EBM process parameters is evaluated in order to understand the effects of the residual stresses on part integrity. [ABSTRACT FROM AUTHOR]

The American standard ASTM E837 presents a standard procedure to determine residual stresses in isotropic materials using the incremental hole drilling technique (IHD). The standard, however, presents limitations regarding its applicability, such as those related with the thin thickness of the samples. According to this standard, in depth non uniform residual stresses can only be determined, roughly, in plates where the thickness is greater than the mean diameter of the strain gage rosette used. This limitation excludes important experimental cases and, therefore, deserves to be investigated. In this work this limitation is numerically and experimentally investigated in detail, considering the case of residual stresses induced by laser shock peening (LSP) in aluminum alloy 7075-T651 plates. The obtained results using the incremental hole drilling technique (IHD), based on the integral method, are benchmarked against the results of several diffraction techniques, used as reference, and a procedure to correct the experimentally determined strain-depth relaxation curves, to accurately still apply the ASTM E837 standard procedure is discussed and validated. [ABSTRACT FROM AUTHOR]

Among the various Additive Manufacturing (AM) technologies available for metal part production, powder bed processes are the most promising for industrial mass production. However, one obstacle to the widespread adoption of AM technologies is the effect of the residual stress state on the integrity and lifetime of parts. The residual stress state is influenced to a great extent by the geometry and orientation of the part, and such conditions as the distance of the part regions from the building platform or geometrical constraints may change the stress values and distribution. This work describes an experimental activity that has made it possible to draw the trend of the residual stress beneath the surfaces of thin samples produced in AISi10Mg alloy through a Laser Powder Bed Fusion (L-PBF) process, in order to evaluate how stresses are altered by different geometrical constraints. [ABSTRACT FROM AUTHOR]

The ultrasonic stress relief process was introduced to relieve the residual stress in the TC4 titanium alloy subjected to the laser surface irradiation. And the hole drilling method was used to evaluate the residual stress in the TC4 titanium alloy. The results show that the larger tensile residual stress induced by the high energy laser can be effectively relieved by the ultrasonic stress relief. In addition, the effect of the ultrasonic stress relief can be improved by increasing the ultrasonic vibration energy imposed into the TC4 titanium alloy. The findings confirm that the ultrasonic stress relief is promising to be used to relieve the residual stress in TC4 titanium alloy during the processing and manufacturing process. [ABSTRACT FROM AUTHOR]

Copyright of China Plastics / Zhongguo Suliao is the property of Journal Office of CHINA PLASTICS and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Measurement of highly spatially resolved residual stresses is a crucial task for tailoring the stress state during manufacturing to improve mechanical performance of metallic objects. Especially in sheet metal forming or blanking with sheet thicknesses down to 0.1 mm, a highly resolved pattern of the stress distribution over the sheet thickness is required for optimisation. For this purpose, a method which uses an extended Hertzian theory for calculating residual stresses from the results of nanoindentation is used to measure the stress profile in metallic cylinders. For verification of the indentation results, hole drilling is utilised to determine residual stresses in the near-surface area. This method provides similar assumptions about the stress state (biaxial). The measuring principle is also based on correlations between mechanical behaviour of the material and the residual stress distribution. The results yield a good accordance of the measured values despite the different scales of measurement. Therefore, a highly spatially resolved measurement of residual stresses with nanoindentation is possible and shows comparable values to the classic hole drilling technique. [ABSTRACT FROM AUTHOR]

In this paper, fiber waviness, as one of the most frequently occurring defects in fiber reinforced composites, is numerically investigated with regard to the formation of residual stresses in fiber metal laminates. Furthermore, the prediction of the residual stress state in the thickness direction by means of the simulated hole drilling method is studied. To this regard, a global-local finite element analysis based on the submodel technique is presented. The submodel technique essentially consists of two governing steps: In the first step, a global model is first utilized to calculate and analyze the residual stress distribution and deformation in the intrinsically joined hybrid structure. Effective cure-dependent thermo–elastic properties predicted by a numerical homogenization procedure were used to simulate the curing-process and analyze the residual stresses state. However, the dimension of the intrinsically manufactured hybrid plate is large compared to the diameter of the drilled hole (2 mm), so that a local model is necessary, which provides only a geometric partial portion of the global model. The local model takes the global stress state into account and is subsequently used to simulate the incremental hole drilling method with a refined mesh discretization. The production-related fiber waviness is modeled by an element-wise orientation approximating a sinus function. In order to validate the global-local modeling approach, a comparison between numerical results and experimental data from literature is presented. The comparison between global residual stress state (global model) and the simulated hole drilling method (local model) is used to assess the applicability and reliability of the hole drilling method in case of fiber waviness. It is found that an in-plane fiber waviness leads to a rather low variance of residual stresses over thickness. In case of an out-of-plane fiber waviness, oscillating residual stress fields occur over the entire thickness along the fiber direction. Moreover, the current limits of the incremental hole drilling method could be pointed out by the presented investigations. It is seen that the simulated results of the incremental hole drilling method are sensitive to waviness, even if the amplitude-wavelength-ratio is small. Without further adjustment of the calibration coefficients the oscillating stress and strain fields lead, in particular fiber waviness in thickness direction, to unreliable predictions. For the experimental application it can be concluded that the specimens have to be carefully examined with regard to fiber waviness.

Different studies have emphasized the technological relevance of residual stresses in engineered surfaces, such as thermally sprayed coatings, and their effect on the fracture and fatigue behavior. In arc-sprayed coatings, the microstructural characteristics and resulting residual stresses are determined primarily by the inherent process characteristics and feedstock material. With the scope of this work, a study on the residual stress field in coatings formed by an arc spraying process for different electric parameter settings has been carried out using different wire configurations. Thus, iron-based cored wires with different grain-sized tungsten carbides as filler material were used as feedstock. The coatings are mainly composed of eutectic carbides, and eta carbides such as M6C, M12C, or M23C and some iron-rich oxide phases, as well as characterized by an inhomogeneous, lamellar microstructure. The results demonstrated that the magnitude of the residual stresses in the coating depends on the carbide grain size fraction used as filling for cored wires. A smaller carbide grain size leads to a more pronounced dissolution of eutectic carbides, resulting in the formation of eta carbides, which in turn is accompanied by decreased tensile residual stresses across the coating. With respect to the spray parameter settings, reduced tensile residual stresses are observed when an increased voltage is applied, which can be attributed to phase evolution phenomena during spraying and thermal effects on the substrate-coating system. [ABSTRACT FROM AUTHOR]

Numerical evaluation of the reliable measurement range of residual stresses by probe-hole method is obtained using the finite element method. It is demonstrated that recovery of the ratio of components of the stress state when using the approach based on basis functions is performed with accuracy sufficient for practical application. Precise recovery of values of the components of the stress state is possible with the effective intensity of residual stresses in the range of 0–0.7 of the tensile yield of the studied material. [ABSTRACT FROM AUTHOR]