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Title: Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

Abstract

While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here we report an initial reproducibility experiment focused on contour method data analysis and residual stress calculation. The experiment uses surface topography data from a physical process simulation of elastic-plastic beam bending. The simulation provides surface topography, for input to the contour method data analysis, as well as a known residual stress field with 130 MPa peak magnitude. Additionally, to increase realism, noise and specific artifacts are added to the topography data. A group of participants received the topography data (without the known residual stress), independently analyzed the data, and submitted results as a two-dimensional residual stress field. Analysis of submissions provides a group average residual stress field and the spatial distribution of reproducibility standard deviation. The group average residual stress agrees with the known stress in magnitude and spatial trend. The reproducibility standard deviation ranges from 2 to 54 MPa over the measurement plane, with an average of 5.4 MPa. Reproducibility standard deviation is smaller in the cross-section interior (≤ 5 MPa), modest near local extrema in the stress field (5 to 10 MPa), and larger near the cross-section boundariesmore » (10 to 30 MPa). Overall, the largest values of reproducibility standard deviation (up to 54 MPa) occur in limited areas where artifacts had been added to the topography data; while some participants identified and removed these artifacts, some did not, leading to systematic differences that elevated the standard deviation.« less

Authors:
 [1];  [2];  [2];  [3];  [4];  [5];  [6]; ORCiD logo [1]
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  1. Univ. of California, Davis, CA (United States)
  2. Southwest Research Inst. (SwRI), San Antonio, TX (United States)
  3. Los Alamos National Lab. (LANL), Los Alamos, NM (United States)
  4. Open Univ., Milton Keynes (United Kingdom). StressMap
  5. Air Force Research Lab. (AFRL), Wright-Patterson AFB, OH (United States)
  6. Hydro-Quebec Research Inst., Varennes, QC (Canada)
Publication Date:
Research Org.:
Los Alamos National Lab. (LANL), Los Alamos, NM (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1671104
Report Number(s):
LA-UR-20-24098
Journal ID: ISSN 0014-4851
Grant/Contract Number:  
89233218CNA000001
Resource Type:
Accepted Manuscript
Journal Name:
Experimental Mechanics
Additional Journal Information:
Journal Volume: 60; Journal Issue: 6; Journal ID: ISSN 0014-4851
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; contour method; residual stress; reproducibility; precision; uncertainty

Citation Formats

D’Elia, C. R., Carlson, S. S., Stanfield, M. L., Prime, M. B., Araújo de Oliveira, J., Spradlin, T. J., Lévesque, J. B., and Hill, M. R. Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation. United States: N. p., 2020. Web. doi:10.1007/s11340-020-00599-0.
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D’Elia, C. R., Carlson, S. S., Stanfield, M. L., Prime, M. B., Araújo de Oliveira, J., Spradlin, T. J., Lévesque, J. B., & Hill, M. R. Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation. United States. https://doi.org/10.1007/s11340-020-00599-0
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D’Elia, C. R., Carlson, S. S., Stanfield, M. L., Prime, M. B., Araújo de Oliveira, J., Spradlin, T. J., Lévesque, J. B., and Hill, M. R. Wed . "Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation". United States. https://doi.org/10.1007/s11340-020-00599-0. https://www.osti.gov/servlets/purl/1671104.
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@article{osti_1671104,
title = {Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation},
author = {D’Elia, C. R. and Carlson, S. S. and Stanfield, M. L. and Prime, M. B. and Araújo de Oliveira, J. and Spradlin, T. J. and Lévesque, J. B. and Hill, M. R.},
abstractNote = {While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here we report an initial reproducibility experiment focused on contour method data analysis and residual stress calculation. The experiment uses surface topography data from a physical process simulation of elastic-plastic beam bending. The simulation provides surface topography, for input to the contour method data analysis, as well as a known residual stress field with 130 MPa peak magnitude. Additionally, to increase realism, noise and specific artifacts are added to the topography data. A group of participants received the topography data (without the known residual stress), independently analyzed the data, and submitted results as a two-dimensional residual stress field. Analysis of submissions provides a group average residual stress field and the spatial distribution of reproducibility standard deviation. The group average residual stress agrees with the known stress in magnitude and spatial trend. The reproducibility standard deviation ranges from 2 to 54 MPa over the measurement plane, with an average of 5.4 MPa. Reproducibility standard deviation is smaller in the cross-section interior (≤ 5 MPa), modest near local extrema in the stress field (5 to 10 MPa), and larger near the cross-section boundaries (10 to 30 MPa). Overall, the largest values of reproducibility standard deviation (up to 54 MPa) occur in limited areas where artifacts had been added to the topography data; while some participants identified and removed these artifacts, some did not, leading to systematic differences that elevated the standard deviation.},
doi = {10.1007/s11340-020-00599-0},
journal = {Experimental Mechanics},
number = 6,
volume = 60,
place = {United States},
year = {Wed Jun 03 00:00:00 EDT 2020},
month = {Wed Jun 03 00:00:00 EDT 2020}
}
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https://doi.org/10.1007/s11340-020-00599-0
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Works referenced in this record:

Cross-Sectional Mapping of Residual Stresses by Measuring the Surface Contour After a Cut
journal, November 2000

  • Prime, M. B.
  • Journal of Engineering Materials and Technology, Vol. 123, Issue 2
  • DOI: 10.1115/1.1345526

Validation of a Contour Method Single-Measurement Uncertainty Estimator
journal, March 2018

Estimation of Uncertainty for Contour Method Residual Stress Measurements
journal, December 2014

Repeatability of Contour Method Residual Stress Measurements for a Range of Materials, Processes, and Geometries
journal, May 2018

  • Olson, Mitchell D.; DeWald, Adrian T.; Hill, Michael R.
  • Materials Performance and Characterization, Vol. 7, Issue 4
  • DOI: 10.1520/MPC20170044

Repeatability of the Contour Method for Residual Stress Measurement
journal, May 2014

Towards good practice guidelines for the contour method of residual stress measurement
journal, August 2014

  • Hosseinzadeh, Foroogh; Kowal, Jan; Bouchard, Peter John
  • The Journal of Engineering, Vol. 2014, Issue 8
  • DOI: 10.1049/joe.2014.0134
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