Question 1

What are residual stresses and why do they remain after loading is removed?

Accepted Answer

Residual stresses are stresses that persist in a structure even after the original load is removed. They arise from uneven plastic deformations across different parts of a structure. When a rod is stretched beyond its yield point, it permanently deforms and doesn't regain its original length. These remaining stresses exist because plastic deformations are permanent and distributed unevenly throughout the material.

Question 2

How does welding create residual stresses in a plug and plate assembly?

Accepted Answer

During welding, the plug's temperature increases significantly, reducing both the modulus of elasticity and stress. As the plug cools post-welding, its elasticity increases, causing yielding at a constant stress level. This creates residual stress in the plug and weld close to the steel's yield strength. The cooling process generates stresses that remain locked in the material after the weld solidifies.

Question 3

Why do cast or hot-rolled metals develop residual stresses during cooling?

Accepted Answer

During cooling of cast or hot-rolled metals, outer layers cool faster than the inner core, regaining stiffness more quickly. On returning to room temperature, the inner core contracts more than the outer layers, resulting in residual longitudinal tensile stresses at the inner core. The outer layers develop residual compressive stresses. This differential cooling creates opposing stress distributions throughout the material.

Question 4

What is the relationship between plastic behavior and residual stress formation?

Accepted Answer

Residual stresses form because plastic deformations are permanent and uneven across a structure. When material undergoes plastic behavior beyond its yield point, it cannot fully recover its original shape or stress state. The permanent deformation from plastic behavior locks stresses into the material, creating residual stresses that persist even after external loads are removed.

Question 5

How can large residual stresses be removed from a structure?

Accepted Answer

Large residual stresses are removed through reheating and slow cooling. This process allows the material to relax and redistribute stresses more uniformly. By raising the temperature and cooling gradually, the material regains ductility and can relieve the locked-in stresses. This thermal treatment is essential for ensuring the reliability and durability of structures and components in engineering applications.

Question 6

Why is understanding residual stresses important in engineering design and manufacturing?

Accepted Answer

Understanding and managing residual stresses is crucial because they affect structural reliability and durability. Residual stresses can influence how materials respond to future loads and environmental conditions. They may cause unexpected failures or reduce component lifespan if not properly managed. Engineers must account for residual stresses during design and manufacturing to ensure structures perform safely and predictably throughout their service life.

Question 7

How do modulus of elasticity changes during welding contribute to residual stress development?

Accepted Answer

During welding, elevated temperatures reduce the modulus of elasticity in the heated plug region. As the plug cools, the modulus of elasticity increases, causing the material to become stiffer. This stiffness increase combined with thermal contraction forces the material to yield at a constant stress level, generating residual stresses. The variation in elastic properties across the weld zone drives residual stress formation.

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