Residual stresses introduced during quenching process in aluminium gas cylinders contribute to the development of cracks. This may result in leakage or fracture of the cylinders. Finite element studies were conducted to evaluate the effect of the quenching process on through thickness inelastic strain and residual stress distributions in the neck area of the gas cylinder. The numerical modeling and experimental studies confirmed that high level of tensile residual stresses exists at the internal surface of the neck of the aluminium gas cylinders which is susceptible to cracking.

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