Quantifying Three-Dimensional Residual Stress Distributions Using Spatially-Resolved Diffraction Measurements and Finite Element Based Data Reduction

Residual stress can play a significant role in the processing and performance of an engineered metallic component. The stress state within a polycrystalline part can vary significantly between its surface and its interior. To measure three-dimensional (3D) residual stress fields, a synchrotron x-ray diffraction-based experimental technique capable of non-destructively measuring a set of lattice strain pole figures (SPFs) at various surface and internal points within a component was developed. The resulting SPFs were used as input for a recently developed bi-scale optimization scheme McNelis et al. J Mech Phys Sol 61:428-1007 449 (2013) that combines crystal-scale measurements and continuum-scale constraints to determinethe 3D residual stress field in the component. To demonstrate this methodology, the 3D residual stress distribution was evaluated for an interference-fit sample fabricated from a low solvus high refractory (LSHR) polycrystalline Ni-base superalloy.