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Residual stress variations during fabrication
  • Bachelor and Master Thesis
    • Battery research: Selective laser sintering for use in future batteries
    • Evaluation of the influence of particle contamination depending on the separator and compression using the Hi-Pot Test
    • Contacting of metal-polymer current collectors for use in cylindrical cells: Concept development and validation
    • Optimization of a bending test for the mechanical characterization of battery electrodes
    • Influence of cutting process and free cut edge geometry on the Al-5083 fatigue strength
    • Design and testing of a device and method for the in-situ calibration of force sensors in the die casting process
    • Laser beam assembly of lithium metal anodes
    • Laser pretreatment of die-cast aluminium for in-mold assembly with plastic
    • Prediction of component properties in high-pressure die casting using machine learning
    • Remelting effect on temperature field, residual stress, and distortion in WAAM components
    • Residual stress variations during fabrication
    • Conversion and test of a heating system
    • Investigation of the local suitability for adhesive bonding of aluminium die-cast components
    • Investigation of the local suitability for welding of aluminium die-cast components
    • Influence of thermal cutting processes on the quality of the cut edges
    • Toughness of high strength welded steels

Residual stress variations during fabrication

Background

In practice, general structures are fabricated by a series of production processes such as cutting, welding/ joining, and residual stress relieving, etc. In thermal process such as cutting and welding, residual stresses are unavoidably generated in the components. Since residual stresses might affect the structural integrity and service life, the postprocessing heat treatment is usually applied to relieve the generated residual stress in structures. To assess the structural integrity, it is necessary to know the magnitude and distribution of residual stress during fabrication at the design stage.

The samples with designed size are obtained from a big plate by cutting. The generated residual stress in this stage is called initial residual stress. Then, the cut samples are heat treated (annealing) to remove this initial residual stress in some cases. After that, the specimens are welded and the welding residual stresses are generated in the components. Finally, the residual stress relieving is performed to eliminate residual stress. However, there is almost no systematically investigaztion yet to quantitatively show the variation of residual stress during the whole fabrication.

Task

First of all, the designed geometry of samples will be cut and machined from a large plate. After that, the heat treatment will be performed. Then, these samples will be welded using tungsten inert gas welding without the addition of filler wire. Finally, the post-weld heat treatment is performed. Note that the residual stress in the components will be measured by using X-ray diffraction at each stage.

Schematical representation of fabrication flowchart
Schematical representation of fabrication flowchart

In the context of a student thesis the following fields of activity arise:

  • Literature research on this topic
  • Performing manufacturing process experiments
  • Results analyses, discussion, and written elaboration

Amount of work

The scope of the work is scalable and therefore allows for a bachelor’s thesis, student research project, and master’s thesis. A detailed assignment can be requested from the supervising research assistant. The time for familiarization is given under supervision.

Requirements

  • Known requirements of the faculty for the submission of a student research project or thesis.
  • Commitment and fun in production processes.
  • Time for familiarization under supervision.
  • Fluent English and German

Start

The work can start immediately.

Dr. Ing. Jiamin Sun
+ 49 531 391 95513
jiamin.sun(at)tu-braunschweig.de
Dr.-Ing. Jiamin Sun
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