본 연구는 현재 가설되어 가용 중인 프리스트레스트 구조물에 대해서 긴장 응력을 계측하는 방법에 관한 연구를 위해 외부 자화를 이용한 PSC 텐던의 긴장 응력 계측에 관한 연구를 진행하였다. 이에 유한요소해석을 이용하여 PSC 거더에 외부 자화 시 잔존 긴장 응 력을 검출하기 위해 PSC 거더 내부의 PS 텐던까지 영향을 줄 수 있는 코일 배치 및 크기 등을 고려하여 최적의 센서를 설계하였다. 또 한, 유한요소해석을 이용하여 설계한 센서와 동일한 수치 및 재질 데이터를 이용해 이론적 검증을 진행하였으며 타겟 위치에서 자화 의 세기를 계산하였을 때, 유한요소해석 결과와 동일한 결과를 얻어낼 수 있었다. 이를 통해 설계한 센서의 검증 및 비 접촉 외부 자화 EM 센서를 활용하여 PSC I형 거더 내부 텐던의 자화가 가능함을 확인하였다.

In order to investigate the optimum condition of the autofrettage process for the diesel engine fuel injection pipe, different values of autofrettage pressure, pressure rising time, pressure holding time, and repetition of autofrettage process were applied. Autofrettage was performed by applying the hydrostatic internal pressures of 604MPa, 535MPa, 500MPa on the fuel injection pipe, corresponding to theoretical 50%, 30%, and 20% overstrain levels, respectively. The autofrettage residual stresses in the injection pipe were experimentally determined by using X-ray diffractometer. As the overstrain level increased, the magnitude of compressive residual stress at the bore increased. It was found that the rising time to reach the autofrettage pressure, holding time at the autofrettage pressure, and repeated application of the autofrettage pressure on the pipe had no significant influence on the residual stress distributions.

This paper reports the results of an experimental examination using X-rays to test annealing materials for lapped bearing steel (STB2), to confirm the validity of the weighted averaging analysis method. The distribution behavior for the sin diagram and the presence or absence of differences in the peak method, half-value breadth method, and centroid method were investigated. When lapping the annealed bearing steel (STB2) material, a residual stress state with a non-directional steep gradient appeared in the surface layer, and it was found that the weighted averaging analysis method was effective. If there is a steep stress gradient, the sin diagram is curved and the diffraction intensity distribution curve becomes asymmetric, resulting in a difference between the peak method, half-value breadth method, and centroid method. This phenomenon was evident when the stress gradient was more than 2~3 kg/mm2/μm. In this case, if the position of the diffraction line is determined using the centroid method and the weighted averaging analysis method is applied, the stress value on the surface and the stress gradient under the surface can be obtained more accurately. When the stress gradient becomes a problem, since the curvature of the sin diagram appears clearly in the region of sin > 0.5, it is necessary to increase the inclination angle  as much as possible. In the case of a lapping layer, a more accurate value can be obtained by considering  in the weighted averaging analysis method. In an isotropic biaxial residual stress state, the presence or absence of  can be determined as the presence or absence of strain for sin≈0.4.

Aluminum nitride having a dense hexagonal structure is used as a high-temperature material because of its excellent heat resistance and high mechanical strength; its excellent piezoelectric properties are also attracting attention. The structure and residual stress of AlN thin films formed on glass substrate using TFT sputtering system are examined by XRD. The deposition conditions are nitrogen gas pressures of 1 × 102, 6 × 103, and 3 × 103, substrate temperature of 523 K, and sputtering time of 120 min. The structure of the AlN thin film is columnar, having a c-axis, i.e., a <00·1> orientation, which is the normal direction of the glass substrate. An X-ray stress measurement method for crystalline thin films with orientation properties such as columnar structure is proposed and applied to the residual stress measurement of AlN thin films with orientation <00·1>. Strength of diffraction lines other than 00·2 diffraction is very weak. As a result of stress measurement using AlN powder sample as a comparative standard sample, tensile residual stress is obtained when the nitrogen gas pressure is low, but the gas pressure increases as the residual stress is shifts toward compression. At low gas pressure, the unit cell expands due to the incorporation of excess nitrogen atoms.

Application of a very high internal pressure on the thick-walled pressure vessel induces beneficial compressive tangential residual stresses near the bore of the pressure vessel after unloading the internal pressure. However, a reverse yielding due to the Bauschinger effect during the unloading process causes the reduction of the compressive residual stress near the bore. In order to evaluate the autofrettage residual stress distributions of the thick-walled pressure vessel, the Bauschinger effects were considered. Magnitudes of the compressive residual stresses at the bore determined by considering the Bauschinger effects decreased by about 25 percent, compared to the case of linear elastic unloading, i.e., without Bauschinger effects. Measured residual stress distributions agreed fairly well with the calculated distributions considering the Bauschinger effects.

To improve life time of machine components, higher alloy grade materials are used by adding more metal alloy components and content. Also production processes are further complicated and subdivided such as the forging, preliminary heat treatment, quality heat treatment, rough machining and finished machining process. Those reasons become major cause of large stress in the materials, and the residual stress generated during the manufacturing process causes fatal defects, such as crack, surface tear, warping and deformation of the products. It is necessary to evaluate the residual stress on the entire processes, from forging process to final finished machining process. Also in order to avoid those problems caused by residual stresses, it is necessary to know in advance what process is important to be controlled and what parameters affect residual stress. By the hole drilling method, residual stress was measured in each manufacturing process step. In this study, the hardness of the surface, the cutting force test and the metal analysis were performed to clarify the influence of manufacturing process parameters.

The residual stress analysis and fatigue test of a steel plate with a hole were performed in order to investigate the effects of the cold expansion on the fatigue life of the plate. The cold expansion method is a metal forming process by expanding a hole in order to induce compressive tangential residual stresses near the hole. In this research, a S45C steel plate of 3.2 mm thickness with a hole of 4.318 mm diameter was cold expanded by using a mandrel, resulting in a degree of expansion 1.47%. A significant amount of compressive tangential residual stress of 502 MPa at the hole surface was calculated using the finite element analysis and the compressive residual stress was more widely spreaded in the entry and exit planes than the mid plane in the plate thickness. The compressive tangential residual stresses showed a very beneficial influence on the fatigue life of the plate by increasing 1.2 to 2 times longer lives compared to the plate without cold expansion, depending on the applied load levels. Fatigue crack initiated and propagated at the hole surface of the mandrel entrance region, where relatively lower magnitude of compressive residual stress was found than the other region.

This paper investigates the effect of prolonged high temperature exposure on concentric laminated Al2O3-ZrO2 composites. An ultrafine scale microstructure with a cellular 7 layer concentric lamination with unidirectional alignment was fabricated by a multi-pass extrusion method. Each laminate in the microstructure was 2-3μm thick. An alternate lamina was composed of 75%Al2O3-(25%m-ZrO2) and t-ZrO2 ceramics. The composite was sintered at 1500˚C and subjected to 1450˚C temperature for 24 hours to 72 hours. We investigated the effect of long time high temperature exposure on the generation of residual stress and grain growth and their effect on the overall stability of the composites. The residual stress development and its subsequent effect on the microstructure with the edge cracking behavior mechanism were investigated. The residual stress in the concentric laminated microstructure causes extensive micro cracks in the t-ZrO2 layer, despite the very thin laminate thickness. The material properties like Vickers hardness and fracture toughness were measured and evaluated along with the microstructure of the composites with prolonged high temperature exposure.

In this study, the effects of cryogenic treatment cycles on the residual stress and mechanical properties of 7075 aluminum alloy (Al7075) samples, in the form of a tube-shaped product with a diameter of 500 nm, were investigated. Samples were first subjected to solution treatment at 470˚C, followed by cryogenic treatment and aging treatment. The residual stress and mechanical properties of the samples were systematically characterized. Residual stress was measured with a cutting method using strain gauges attached on the surface of the samples; in addition, tensile strength and Vickers hardness tests were performed. The detailed microstructure of the samples was investigated by transmission electron microscopy. Results showed that samples with 85 % relief in residual stress and 8% increase in tensile strength were achieved after undergoing three cycles of cryogenic treatments; this is in contrast to the samples processed by conventional solution treatment and natural aging (T4). The major reasons for the smaller residual stress and relatively high tensile strength for the samples fabricated by cryogenic treatment are the formation of very small-sized precipitates and the relaxation of residual stress during the low temperature process in uphill quenching. In addition, samples subjected to three cycles of cryogenic treatment demonstrated much lower residual stress than, and similar tensile strength compared to, those samples subjected to one cycle of cryogenic treatment or artificial aging treatment.

Gas welding is a very important and useful technology in the fabrication of railroad cars and commercial vehicle structures. However, since the fatigue strength of gas-welded joints is considerably lower than that of the parent material due to stress concentration at the weld, the fatigue-strength assessment of gas-welded joints is very important for the reliability and durability of railroad cars and the establishment of a criterion for long-life fatigue design. In this paper, in order to save time and cost for the fatigue design, an accelerated life-prediction method that is based on the theory of statistical reliability was investigated. Its usefulness was verified by comparing the (Δσa)R-Nf relationship that was obtained from actual fatigue test results with the (Δσa)R-(Nf)ALP relationship that was derived from accelerated life testing. And the reliability of the predicted life was evaluated. The reliability of the accelerated life-prediction on the base of actual test data was analyzed to be (81～86)% of the actual test life of the fillet-type gas welded joint.

Plastic deformation was observed by TEM around the intragranular SiC particles in the matrix for nanocomposite system. The dislocations are generated at selected planes and there is a tendency for the dislocations to form a subgrain boundary structure with low-angel grain boundaries and networks. In this study, dislocation generated in the matrix during cooling down from sintering temperatures by the highly localized thermal stresses within and/or around SiC particles caused from the thermal expansion mismatch between matrix and SiC particle was observed. In monolithic and microcomposite system. These phenomena is closely related to the plastic relaxation of the elastic stress and strain energy associated with both thermal misfitting inclusions and creep behaviors. The plastic relaxation behavior was explained by combination of yield stress and internal stress.

최근에 상용차용 디젤 엔진의 성능 향상을 목적으로 엔진 설계가 급격히 변화되면서 캠 팔로우어(cam follower)와 캠(cam) 사이에 작용하는 접동면 하중의 증가로 접동면에서의 마모가 중요한 문제가 되고 있다. 본 연구에서는 기존의 주절체 및 소결합금 캠 팔로우어에 비해 내마모성이 우수한 세라믹 캠 팔로우어를 개발하였다. 잔류 응력을 완화시켜주는 중간층을 사용하지 않고 질화규소(Si3N4) 팁과 중탄소강을 활성납재를 사용하여 직접 접합후 냉각시키는 과정에서 두 모재의 열팽창계수차에 의한 크라우닝(crowning, R) 이 형성되도록 하였다. 접합에 사용한 중탄소강은 열팽창시 이력(hysteresis) 거동을 나타내었으며, Ac1 변태점인 723˚C 이하에서 접합할 경우 원하는 크라우닝이 형성되었다. 접합온도가 723˚C 이상이 되면 크라우닝 (R) 값이 온도에 따라 지수함수적으로 증가하였으며 이는 중탄소강의 상변태에 의한 열팽창.수축의 이력 특성으로 설명되어질 수 있었다. 규격에 맞는 크라우닝이 형성되는 최적 접합 온도는 700~720˚C의 범위였다. 질화규소와 중탄소강의 직접 접합방법으로 접합과 동시에 크라우닝을 형성시키고 제어함으로써 난가공재인 세라믹을 곡면 가공하지 않고도 적당한 곡률을 갖는 저가의 세라믹 캠 팔로우어를 제조할 수 있었다.

활성금속브레이징법으로 계면접합된 AlN/Cu 접합체의 잔류응력 완화에 미치는 Mo 중간재의 영향을 조사하였다. 유한요소법에 의한 응력 해석과 접합체 강도 측정, 파단면의 관찰을 행하였으며, 이들 결과를 비교, 분석하였다. 응력 해석 결과로부터, Mo 중간재를 사용할 경우 최대 잔류 주응력이 형성되는 위치가 AlN/삽입금속 계면으로부터 삽임금속/Mo 계면을 통하여 Mo 내부로 이동됨을 확인하였다.접합체의 자유표면에 형성되는 인장성분의 응력집중 위치는 Mo 중간재 두께가 증가됨에 따라 Cu/Mo 계면과 Mo/AlN 계면의 두 곳으로 분리되었으며, AlN측 잔류응력의 크기는 크게 감소하였다. 중간재를 사용하지 않은 경우 최대 접합강도가 52 MPa로 낮은 강도를 보였으나, 두께 400μm 이상의 Mo 중간재를 사용한 접합체의 경우, 200 MPa 이상, 최대 275 MPa의 접합강도를 얻을 수 있었다.

Ag-Cu-Ti 삽입금속을 이용하여 제조된 AlN/Cu와 AlN/W 활성금속브레이징 접합체의 잔류응력을 유한요소법으로 탄성 및 탄소성 해석을 행하여 그 결과를 접합강도 측정 결과와 파단 거동 관찰 결과와 비교, 분석하였다. 최대 잔류 주응력의 크기는 AlN/W 접합체보다 모재간 열팽창계수 차이가 큰 AlN/Cu 접합체에서 더 크게 나타났으며, 접합계면에 인접한 AlN 세라믹스 자유표면에 인장 성분의 응력집중이 확인되었다. 모재와 삽입금속의 탄소성 변형을 모두 고려할 경우, AlN/Cu 접합체의 경우 연질의 삽입금속에 의해 최대 잔류 주응력이 감소하여 소성변형에 의한 응력완화 효과가 있음을 확인하였으나, 100μm 이상으로 삽입금속 두께를 증가시키더라도 잔류 주응력의 크기는 더 이상 크게 감소하지 않았다. 측정된 최대 접합강도는 AlN/Cu와 AlN/W 접합체에서 각각 52 MPa와 108 MPa이었으며, 파단 형태는 AlN/Cu 접합체는 AlN 자유표면으로부터 AlN 내부로 큰 각도를 이루면 진행되는 돔형의 파단이, AlN/W 접합체에서는 접합계면의 삽입금속층을 따라 AlN 측에서 파단이 일어나는 형태를 보였다.

잔류응력을 측정하는 비파괴 방법중 Neutron diffraction technique의 발달로 인하여 기존의 X-ray diffraction technique에 비하여 잔류응력 측정가능 두께가 대부분의 물질에 있어서 훨씬 깊어졌다. 비파괴 방법으로 부품내의 잔류응력 분포가 측정되어진 경우, 부품의 가공시 잔류응력의 재분포로 인한 형상의 변화를 정량적으로 예측할 수 있는 방법에 대해 어떠한 경우도 논의된 바 없다. 본 연구에서는 축 방향의 잔류응력이 내재하는 strip의 층 가공시 일어나는 strip의 곡율변화를 정량적으로 예측할 수 있는 수식을 제시하였다. 간단히 컴퓨터 프로그램화 할 수 있는 수식을 전개하므로 써 현장에서 유용하게 이용할 수 있게 하였다.

rf 플라즈마 화학증착을 이용하여 증착된 hydrogenated DLC막의 잔류응력 거동에 대해 조사하였다. 합성된 DLC막의 압축 잔류응력은 이온 에너지뿐만 아니라 이온/원자 유입량 비에 의해 영향을 받는 것으로 조사되었다. 잔류응력의 최대치는 이온/원자 유입량비가 증가할수록 낮은 이온 에너지 구간에서 일어나며 그 값은 증가하였다. 이온 에너지에 따른 DLC막의 결합 구조의 변형을 Raman 스펙트럼을 이용하여 분석하였다. DLC막의 잔류응력은 sp3결합의 net working이 최대가 되는 점에서 최대치를 보이며, 이는 sp3 net working에 의한 부피팽창 요인에 기인하는 것으로 생각된다. DLC막 내의 유입되는 수소는 잔류응력의 직접적인 원인으로 작용하지 않는 것으로 분석되었다.