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Controlling the Cut in Contour Residual Stress Measurements of Electron Beam Welded Ti-6Al-4V Alloy Plates

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Abstract

The multiple cut contour method is applied to map longitudinal and transverse components of residual stress in two nominally identical 50 mm thick electron beam welded Ti-6Al-4V alloy plates, one in the as-welded condition and a second welded plate in a post weld heat treated (PWHT) condition. The accuracy and resolution of the contour method results are directly linked to the quality of the electro-discharge machining cut made. Two symmetric surface contour artefacts associated with cutting titanium, surface bowing and a flared edge, are identified and their influence on residual stresses calculated by the contour method is quantified. The former artefact is controlled by undertaking a series of cutting trials with reduced power settings to find optimal cutting conditions. The latter is mitigated by attaching 5 mm thick sacrificial plates to the wire exit side of the test specimen. The low level of noise in the measured stress profiles for both the as-welded and PWHT plates demonstrates the importance of controlling the quality of a contour cut and the added value of undertaking cutting trials.

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Acknowledgements

P J Bouchard was supported by a Royal Society Industry Fellowship. This paper is published with the permission of BAMTRI.

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Authors and Affiliations

  1. The Open University, Walton Hall, Milton Keynes, MK7 6AA, UK

    F. Hosseinzadeh, P. Ledgard & P. J. Bouchard

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  1. F. Hosseinzadeh
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  2. P. Ledgard
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  3. P. J. Bouchard
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Correspondence to F. Hosseinzadeh.

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Hosseinzadeh, F., Ledgard, P. & Bouchard, P.J. Controlling the Cut in Contour Residual Stress Measurements of Electron Beam Welded Ti-6Al-4V Alloy Plates. Exp Mech 53, 829–839 (2013). https://doi.org/10.1007/s11340-012-9686-1

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  • DOI: https://doi.org/10.1007/s11340-012-9686-1

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