Simulating Residual Stresses Using a Modified Wedge-Loaded Compact Tension Specimen Available to Purchase

Residual stresses are induced in components when fabrication processes produce internal stresses or local deformation and cause accelerated creep damage and cracking during service at elevated temperatures. A method of inducing residual stresses in laboratory fracture specimens is proposed where an oversized wedge is inserted into the crack mouth of a compact tension, C(T), type specimen. In this way the extent of internal stresses can be controlled in order to minimise the level of crack tip plasticity which inherently reduces the remaining strain to failure. Numerical simulations of wedge insertion into specimens made of 316H austenitic stainless steel have been developed to calibrate the wedge insertion process. These models have been experimentally validated using surface strains measured during the wedge insertion, using Digital Image Correlation (DIC), and Neutron Diffraction (ND) measurements. The validated Finite Element (FE) model is used to determine the wedge insertion depth required to maximise the residual stresses without causing significant crack tip plasticity. The validated numerical simulation is used to determine the wedge insertion depths of further wedge-loaded C(T) specimens made from uniformly pre-compressed 316H stainless steel. The reduced creep ductility of this material increases the rate of crack growth under creep conditions. This method of inducing residual stresses with limited crack tip plasticity allows creep crack growth under simulated secondary loading conditions to be investigated without the influence of non-uniform creep ductility caused by work hardening.