i no. 13133 · ,13133 6a. name of performing organization 6b. office symbol 7a. name of monitoring...

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C N TECHECA

and L BU IOU A~ TOH R

I TECHNICAL REPORTi NO. 13133

I RESIDUAL STRESS MEASUREMENTS

I ON M1 TANK WELDMENTS

I SEPTEMBER 1985

IV

'• S. B. CatalanoU.S. Army Tank-Automtotive oan

nl ATITN: AMSTA-RCTMby Warren, MI 48397-5000

lSIBTOR APPROVED FRPUBLIC RELEASE • •G• • .. Li

lsTIUINIS UNIMITE ...... 12 4 1 4U.S. ARMY TANK-AUTOMOTIVE COMMANDRESEARCH AND DEVELOPMENT CENTERWarren, Michigan 48397-5000RerdcdFo

Best Available Copy

NOTICES

The findings in this report are not to be construed as an officialDepartment of the Army position.

Mention of any trade names or manufacturers in this report shall not beconstrued as advertising nor as an official indorsement of approvalof such products or companies by the U.S. Government

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Approved for Public Release"4. PERFORMING ORGANIZATION REPORT NUMBER(S) 5. MONITORING ORGANIZATION REPORT NUMBER(S)

,131336a. NAME OF PERFORMING ORGANIZATION 6b. OFFICE SYMBOL 7a. NAME OF MONITORING ORGANIZATION

U. S. Army Tank-Automotive (if applicable)

ConmTnd AMSTA-RCM6c. ADDRESS (City, State, and ZIP Code) 7b. ADDRESS (City, State, and ZIP Code)

Warren, Michigan 48397-5000

Ba. NAME OF FUNDING/SPONSORING 8b. OFFICE SYMBOL 9. PROCUREMENT INSTRUMENT IDENTIFICATION NUMBERORGANIZATION U.S. Army Tank- (If applicable)

Automotive Command, RD&E Center AMSTA-RCM _.._

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PROGRAM PROJECT TASK WORK UNIT.ELEMENT NO. NO. NO. ACCESSION NO.

Wlarren, Michigan 48397-5000 ....I11. TITLE (Include Security Classification)

Residual Stress Measurements on M! Tank Weldments

12. PERSONAL AUTHOR(S)S. B. Catalano13a. TYPE OF REPORT 13b. TIME COVERED 14. DATE OF REPORT (Year, Month, Day) 15. PAGE COUNTFinal Technical FROM I Apr Ta0 Sep 8 1 1985 September 30 4416. SUPPLEMENTARY NOTATION

"17. COSATI CODES 18. SUBJECT TERMS (Continue on reverse if necessary and identify by block number)

FIELD GROUP SUB-GROUP

1\11 Tank, Weldments, Residual Stress, X-Ray Diffraction19. ABSTRACT (Continue on reverse if necessary and identify by block number)

Residual strcss Dývels were ircasured on four weldrent areas of the M! tank--two on the hulland two on the turret. Measurem*ents were performed on preexisting tanks as well as oncurrent production runs. TwI hulls and two turrets of preexisting tanks were measured; 1

three hulls and two turrets of current production runs were measured. Measurements wereperformed on the weld nucclet aand heat-affected zones using portable X-ray diffractionequipment. A total of 142 measlrements were performed. Only six measurements exhibitedtensile residual stresses; t' ; . remainder exhibited compressive residual stresses. The highesttensile residual stress obsc'_ ved was 47,000 psi. Weldment areas measured weLre:

"* race ring to forward glacis;"* turret roof plate joint;"* gunner primary siahLc to frontal slope plate; and"* side plate to front rertion of hull.

20. DISTRIBUTION/AVAILABILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATION

(RUNCLASSIFIED/UNLIMITED 0i SAME AS RPT. 0] DTIC USERS Unclassified22a. NAME OF RESPONSIBLE INDIVIDUAL 22b. TELEPHONE (Include Area Code) 22c. OFFICE SYMBOL

aivatore B_ C'-atalano J313) 574-5814 AMSTA-RCMDD FORM 1473,84 MAR 83 APR edition may be used until exhausted. SECURITY CLASSIFICATION OF THIS PAGE

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2

PREFACE

This effort was funded under the Manufacturing Methods & Technology (MM&T)program "Ml Residual Stress (Welding Process)" for the ManufacturingTechnology Branch (AMSTA-TMM), TACOM, Warren, Michigan. It was a six-montheffort covering the period 1 April through 30 September 1985. Appreciation isextended for the priviledge and opportunity of working on this challengingproject.

Dr. Herbert Dobbs, Technical Director, R&D Center, TACOM, is to be thanked forhis interest in this work. Mr. Donald Cargo, Director for Design andManufacturing Technology, TACOM, is to be thanked for his invitation to workon this project and for his interest and timely support. Messrs. B.A. Schevo,D. Pyrce, and G. MacAllister are to be thanked for their advice and direction.Messrs. T. Dean and D. Kendal are to be thanked and complimented for theirexpedience in locating and providing access to MI tanks at the Lima Army TankPlant, Lima, Ohio and at the General Dynamics Groesbeck facility in Warren,Michigan for this study. Acknowledgements are also extended to Mr. P. Gherian,Q.A. Engineer, Lima Army Tank Plant for activities performed as the point ofcontact in arranging for time and space to perform required measurements on Mltanks in the General Dynamics Plant, Lima, Ohio. Appreciation and thanks areextended to Mr. C. Lambright, American Analytical Corp., for diligence inperforming the contracted effort in the measurement of residual stresses withportable X-ray diffraction equipment.

3

3

THIS PAGE LEFT BLANK INTENTIONALLY

4

TABLE OF CONTENTS

Section Page

1.0. INTRODUCTION ................. ........................ . .11

1.1. Residual Stress ...... ..................... ........ .. 11

1.2. Residual Stress in Weldments ......... ................ . 111.3. M1 Hull and Turret ............. ..................... ... 111.4. Measurement of Residual Stress ....... ............... ... 11

2.0. OBJECTIVE ................ .......................... ... 15

3.0. CONCLUSIONS .................... ......................... 15

4.o. RECOMMENDATIONS .............. ....................... ... 15

5.0. DISCUSSION ................. ......................... ... 165.1. Stress Direction ............... ...................... .. 165.2. Surface Considerations ........... ................... ... 165.3. X-ray Beam Size ................ ...................... .. 175.4. Approach ..................... ........................... 175.5. Equipment .................. .......................... .. 175.5.1. Electropolishing Equipment ......... ................. ... 175.5.2. X-ray Diffraction Equipment ........ ................. ... 195.6. Procedure .................... .......................... 195.6.1. Instrument Calibration ........... ................... ... 195.6.2. Surface Preparation .............. .................... .. 195.6.3. Instrument Positioning .... ................ . ....... .. 19

6.0. RESULTS ...................... ........................... 19

LIST OF REFERENCES ....................... ........................ 43

DISTRIBUTION LIST ................ ....................... .. Dist-1

5


6

LIST OF ILLUSTRATIONS

Figure Title Page

1-1. Weldment Cross-Section with Residual Stress Isostress Plot . . 12

1-2. MIAl Welding Isometric, Turret Structure; Outer Roof ........ 13

1-3. tIAI Welding Isometric, Hull Structure ..... ............ .. 14

5-1. Electropolishing Equipment ..... ...................... 18

5.2. Portable X-ray Analyzer for Residual Stress (PARS) .......... 20

6-1. Data Sheets for Current Production MI Tanks .............. .. 21

6-2. Data Sheets for Current Production MI Tanks ..... .......... 23

6-3. Data Sheets for Current Production ML Tanks .............. .. 24

6-4. Data Sheets for Current Production MI Tanks .............. .. 25

6-5. Data Sheets for Current Production Ml Tanks .............. .. 26



6-8. Data Sheets for Current Production Ml Tanks ..... .......... 29

6-9. Data Sheets for Current Production MI Tanks .............. 30

6-10. Data Sheets for Preexisting Ml Tank Weldments ............. .31

6-11. Data Sheets for Preexisting MI Tank Weldments ..... ......... 32

6-12. Data Sheets for Preexisting MI Tank Weldments ............ .. 33


6-14. Data Sheets for Preexisting Ml Tank Weldments ............ .. 35

6-15. Data Sheets for Preexisting Ml Tank Weldments ............ .. 36


6-17. Histogram for Data from Current Production MI Tank Weldments . 38

6-18. Histogram for Data from Preexisting Ml Tank Weldments ........ 39

7


• | n n

LIST OF TABLES

Table Title Page

6-1. Statistical Data: Residual Stress, Current ProductionMI Tank Weldments .............. ....................... .40

6-2. Statistical Data: Residual Stress, Preexisting MlTank Weldments ................. ........................ .. 41

9


10

1.0. INTRODUCTION

1.1. Residual Stress

Stresses remaining within a material after all external forces have beenremoved are termed residual stresses. Certain operations (e.g., heattreatment, welding, rolling, drawing, forging, casting, machining,sand-blasting, shot-blasting, shot-peening, etc.) performed on a metal partcan leave it in a stressed condition which persists in the absence of externalforces. Measurements performed at the U.S. Army Tank-Automotive Command(TACOM), Warren, MI, on T-142 track pins illustrate the effect manufacturingprocesses such as furnace-hardening, induction-hardening, straightening,grinding and shot-peening have on surface residual stress of the pin.,Residual stresses in materials arise also in service. 2 Residual stresses canbe of an undesirable nature or concentration level, adversely affectingfunctional performance and durability. Cumulative high residual stresses andhigh dynamic stresses (in service) may exceed design load limits of the part.

1.2. Residual Stresses in Weldments

Residual stresses are produced in weldments by local thermal expansion,plastic deformation, and subsequent shrinkage upon cooling. Heat-affectedareas adjacent to a weld nugget are nearly always areas of tensile residualstress, and can reduce fatigue life of the weldment. With no external forcesapplied, the weldment is in equillibrium (i.e., not in motion) and tensileresidual stresses in the vicinity of the weldment are balanced by compressiveresidual stresses in regions elsewhere in the weldment. Measurementsperformed at TACOM on a cross-section of the weldment illustrate the locationof tensile and compressive residual stresses in the vicinity of a weldnugget. 3 Residual stress isostress lines of said cross-section are shown inFigure 1-1. The heavy weight solid lines designate the zero level of residualstress. The thin weight solid lines designate areas of compressive residualstress. The dashed lines designate areas of tensile residual stress. Sincefatigue failures never start in an area under compression, weldment fatiguelife can be substantially increased by inducing a surface compressive residualstress (via shot-peening) on weldment surfaces that otherwise would remaintensile.

1.3. Ml Hull and Turret

The hull and turret of the Ml tank are welded structures. Figure 1-2 is awelding isometric drawing of the turret structure (outer roof portion).Figure 1-3 is a welding isometric drawing of the hull structure. Eachweldment in the hull and turret is a potential area of surface tensileresidual stress.

1.4. Measurement of Residual Stress

Nondestructive measurement of the surface residual stresses can beaccomplished with an X-ray diffraction technique. The method used is theDebye-Scherrer powder X-ray diffraction method. The equipment used has beenminiaturized and made suitable for nondestructive field measurement ofresidual stresses. Specifics of the X-ray diffraction method will not be

P -. q

S'FN . . . .

\. . . . . . . . . .,. . . ..

Figure 1-1. Weldment Cross-Section with Residual Stress Isostress Plot

12

-Th-cET R OOF P 1r aT

Figure 1-2. MIA1 Welding Isometric Turret Structure; Outer Roof

13

FA'n# PORT/OW cF IUtiL

Figure 1-3. MIA1 Welding Isometric, Hull Structure

14

developed or discussed in detail in this report; the information is plentifulin published text books and open literature. References 2, 4, and 5 are ofparticular value in this regard. Suffice it here to say that thelmethod usesBragg's Law: n A = 2 d sin 0 , where n = an integer, \ - X-ray wavelength, d = atomic interplanar spacing, and -& the angle of X-ray incidencewhich results in a reflected diffraction peak. Material strain causes a shiftin the value of -& Strain may be calculated from the shift in-& . Throughuse of elastic theory, strain can be used to caluclate stress present,regardless of whether it be residual stress or applied stress. The equipmentused in this effort was instrumented with an on-board computer to perform therequired calculations.

2.0. OBJECTIVE

The objective of this effort was to measure residual stress level on Ml tankweldments. Measurements were performed on preexisting tanks as well as oncurrent production runs. The weldments selected for measurement were:

* Race ring to forward glacis (roll homogeneous armor to cast armor);

* Gunner primary sight to frontal slope plate (casting to two wroughtplates);

* Side plate to front portion of hull;

* Turret roof plate joint.

3.0. CONCLUSIONS

A total of 67 residual stress measurements were performed .on early model(preexisting) MI tanks. Only two of these measurements revealed tensileresidual stresses; the rest were compressive. The greatest tensile residualstress level was 13,000 psi; the greatest compressive residual stress levelwas 134,000 psi. A total of 75 residual stress measurements were performed oncurrent production MI tanks. Only four of these measurements revealed tensileresidual stresses; the rest were compressive. The greatest tensile residualstress level was 47,000 psi; the greatest compressive residual stress levelwas 154,000 psi. The conclusion to be drawn from these data is that nodetrimental level of residual stress was observed on the weldments measured.The tensile readings observed were not of a serious magnitude; the compressivereadings observed are beneficial.

4.0. RECOMMENDATIONS

The weldment areas measured in this effort were identified as being the bestpossible candidates for this study. The X-ray equipment used wasstate-of-the-art equipment. The contractor (American Analytical Corp.) is oneof this country's leaders in the residual stress field. The data obtainedindicate no detrimental levels of residual stresses being present in theseweldments. These findings support the recommendation that no correctiveaction is required at this time. It should be pointed out, however, that from

15

the outset, it was expected that tensile residual stresses would have beenobserved in heat-affected zones of the weldments. Having observedpredominantly compressive readings indicates that factors other than weldingprocess factors may be present. It is believed that said factors are relatedto other manufacturing processes which follow the welding process. It isknown, for example, that the entire hull and entire turret are shot-blastprior to painting to accomplish enhanced paint adherance. Shot-blasting isknown to induce compressive residual stresses. If it should become necessaryto follow residual.stress level as a function of the various processing stepsthat may be present from welding to painting, it is recommended that aproposal be submitted and funding allocated for this endeavor.

iI

5.0. DISCUSSION

The X-ray measurement of residual stress involved X-ray diffractiontechniques. X-ray diffraction differs from X-ray radiography in that itinvolves surface and near-surface reflections of X-rays; X-ray radiographyinvolves penetration of material thicknesses to form images on films or otherdetecting systems. Diffraction employs much lower voltages on the X-ray tubeas well as different X-ray tube types. The X-ray radiation used in this studyis long wavelength, sometimes referred to as soft X-ray and is useful formeasuring surface residual stress; it is not at all useful for radiographicpurposes. For this reason, special armor configuration was not in jeopardy ofbeing revealed in this work.

5.1. Stress Direction

Residual stress has direction as well as magnitude. Measurement of residualstress in a specified direction with X-ray diffraction equipment isaccomplished by rotational orientation/alignment of equipment with respect tothe item/part being measured. The stress direction of interest in this effortis perpendicular to the weld nugget since this is the direction of stressescausing typical weldment cracking. All but three of the measurementsperformed in the work effort reported here were perpendicular to the weldnugget; these three were parallel to the weld nugget.

5.2. Surface Considerations

Fatigue cracking in materials is known to originate at the surface. It isalso known that the surface of the heat-affected zone of a weldment cancontain high tensile residual stresses; these can, in some cases, be largeenough to cause cracking in the heat-affected zone upon cool down afterwelding. For these reasons, the surface of the weldments in the Ml tank wouldbe of most interest in this M1 weldment residual stress study. However, oneshould electropolish a few thousandths of an inch of material away prior tomeasuring stress since the residual stress exactly at the surface wouldreflect random/extraneous residual stress. Examples of random/extraneouslyinduced residual stresses are those induced by sanding away rust, use of slaghammer, and use of air operated wire peener. In the work effort here, thesurface was electropolished from 4 to 10 thousandths of an inch prior tomeasurement; in a few cases, electropolishing was deeper. Only onemeasurement was performed without first electropolishing the surface.

16

5.3. X-ray Beam Size

The isostress plot, referred to earlier in Figure 1-1, illustrates the steepstress gradients present in the vicinity of a weldment. For this reason, areasonably small diameter X-ray beam should be used when measuring residualstresses in the vicinity of weldments. The trade-off, however, is that longerexposure times are required for smaller X-ray beam sizes. The beam size usedin this effort was approximately 1/8 inch in diameter; the exposure times wereapproximately 5 minutes. Penetration of the beam was only about 1/1000 of aninch. Five readings were taken with a smaller X-ray beam size (using a 0.090inch collimator). Each residual stress measurement taken is valid only forthe weldment area defined by the beam size and penetration depth. For thisreason, readings at many different spots are required to characterize theweldment in question.

5.4. Approach

Current production Ml tanks were obtained for this effort from the Lima ArmyTank Plant (LATP), Lima, OH. Preexisting MI tanks were obtained from GeneralDynamics, Warren, MI. In both cases, the hulls and turrets were separate(i.e., not in the married configuration) and without track. This wasaccomplished at LATP by intercepting hulls and turrets on the production lineafter welding, but prior to painting; the preexisting tanks were beingrefurbished and had already been appropriately disassembled. Paint had to beremoved from the preexisting tanks prior to performing residual stressmeasurement, but not from the current production tanks, since they had not yetbeen painted. Paint removal was accomplished in some cases with paintremover. However, this was not a time effective method and was abandoned infavor of using an air-driven wire brush. Small areas about 1/4 inch indiameter were then electropolished at each position about the weldment onwhich residual stress measurements were to be performed. The portable X-rayequipment was then positioned at each spot, measurements were taken, and thedata were recorded.

5.5. Equipment

5.5.1. Electropolishing Equipment. Electropolishing was accomplished withportable equipment manufactured by Struers Inc., Cleveland, OH. (A photographof the equipment is shown in Figure 5-1.) It consisted of an electrical powersupply unit and an electrolyte container with recirculating pump andpencil-shaped polishing probe. The polishing probe was connected to theelectrolyte container via plastic tubing. In use, the probe was placed on theobject to be electropolished, and the power supply was turned on for acalibrated length of time to achieve the desired depth of polishing, theelectrolyte and appropriate voltage being furnished at the probe for thispurpose. The polished area measured 0.4 cm2 . Various electrolyte recipes areavailable. The recipe for the electrolyte used in this work consisted of90 ml distilled water, 730 ml ethhanol (ethyl alcohol), 100 ml butylcellosolve,and 78 ml perchloric acid.

17

Figure 5-1. Electropolishirig Equipme~nt

18

5.5.2. X-ray Diffraction Equipment. Residual stress measurement wasaccomplished using a portable X-ray analyzer for residual stress (PARS) unit.The PARS system was developed at Northwestern University for the Office ofNaval research. The American Analytical Corp. was contracted to furnish theequipment and to perform the measurements. A feature of this equipment thatpermits its small size and portability is the use of a position sensitivedetector (PSD). When used in conjunction with a multichannel analyzer, iteliminates the bulky goniometer used in conventional X-ray diffractometersused to display diffraction peaks. The electronics supporting the PARS is notportable; it is mounted in an electronic instrument relay rack on casters andconsists of an X-ray generator (i.e., high voltage power supply), a videodisplay of the diffraction peak, a multichannel analyzer, a computer, and aprinter. The X-ray tube and PSD are assembled into one portable unit and areattached to the supporting electronics via long cable making it possible tomove the X-ray tube and PSD without also moving the electronics. A photographof the X-ray tube and PSO are shown in Figure 5-2. A chromium target X-raytube and a vanadium filter are used to achieve approximate monochromaticradiation. Operational voltages and current used were 35 kilovolts and 1.7milliamperes.

5.6. Procedure

5.6.1. Instrument Calibration. Prior to performing residual stressmeasurements, reference samples of known value were used to check calibrationof the PARS unit. At LATP, the contractor's compressive reference sample wasused. It was used at the beginning of the first day and at the end of thelast day. TACOM's reference samples were used at General Dynamics. One ofthem was a zero level reference sample, one was a high tensile level referencesample, and the third was a high compressive level reference sample.

5.6.2. Surface Preparation. Surface preparation consisted of paint removalif required, and electropolishing as described in section 5.2.

5.6.3. Instrument Positioning. Due to steep stress gradients in and aroundthe weldments, it is imperative that the X-ray equipment be mounted firmly soas to prevent any movement or vibration during X-ray exposure. This wasaccomplished by firmly clamping the PARS unit to a drill stand, andpositioning this assembly appropriately for each measurement performed.

6.0. RESULTS

The results of this effort are as stated in section 3.0.; the data supportingsaid results are in the data sheets shown in Figures 6-1 through 6-16. Figures6-1 through 6-9 are for current production Ml tanks; Figures 6-10 through 6-16are for preexisting MI tanks. Tables 6-1 and 6-2 are listings of statistics

19

Figure 5-2. Portable X-ray Analyzer for Residual Stress (PARS)

20

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21

derived from data for preexisting and current production M1 tanks. Figures6-17 and 6-18 are histograms of the data. The listings of statistics and thehistograms illustrate that there is no appreciable difference in resultsobtained on preexisting and current production MI tanks. All data areexpressed in KSI units (i.e., units of 1,000 pounds per square inch.) Theaccuracy of all data points is estimated to be plus/minus 10 KSI. A negative(sign) value indicates a compressive residual stress; a positive valueindicates a tensile residual stress. If not otherwise indicated on the datasheets, all electropolish depths are approximately 4/1000 inch, and residualstress directions are perpendicular to the weld nugget. The weld nugget isrepresented by a fine saw tooth line in the sketch on each data sheet.Measurement locations are pictured on the data sheets as dots. Some arepictured as being on the weld nugget, representing those measurements taken onthe nugget. Other dots are pictured as being to either side of the weldnugget, representing measurements taken near the nugget, but off to one side.The latter measurements were located as close to the weld as possible so as tobe positioned in the heat-affected zone of the weldment. An additionalmeasurement was taken at the request of LAT? engineers on hull #3029, whichhad been accidentally dropped in processing. This data point was not includedin the data sheets of this report; it was on a weldment other than thosedepicted in the data sheets. The measurement was taken in the heat-affectedzone of the weldment at a point near the point of impact with the floor. Theweldment was electropolished and the measurement was taken in the directionperpendicular to the weld nugget. The residual stress level was found to be70,000 psi compressive. This data point was included in the statistics ofTable 6-1 ) a- .... as well as in the histogramK of Figureg 6-17. .m-nA

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39

Table 6-1. Statistical Data: Residual Stress, Current Production MlTank Weldments

Statistic Value

N (number of readings) 75

Mean -59.81 KSI

Std. Dev. 40.27 KSI

Skewness 0.205

Kurtosis 2.837

40

Table 6-2. Statistical Data: Residual Stress, Preexisting Ml Tank Weldments

Statistic Value

N (number of readings) 67

Mean -74.52 KSI

Std. Dev. 31.21 KSI

Skewness 0.408

Kur tos is 3.081

41


42

List of References

1 Catalano, S.B., "Track Pin Induced Stress," TACOM Technical Report

12407 (1979)

2 Cohen, J.B. James, M.R. and MacDonald, B.A., "The Measurement of ResidualStress with X-Rays," Naval Research Reviews, Vol XXXI No. 11: Arlington,VA: Department of the Navy, Office of Naval Research, pp. 1-18 (1i78)

3 Catalano, S.B., "Establishment of Rapid X-Ray Diffraction InspectionTechniques for Residual Stresses," TACOM Technical Report No. 12173(1977)

4 Cullity, B.D., "Elements of X-Ray Diffraction," Addison-Wesley PublishingCompany, Reading, Mass. (1957)

5 Society of Automotive Engineers, "The Measurement of Stress by X-Ray -

TR-182," New York, NY (1960)

43


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