All metal forming and machining processes induce residual stress in the final metal component. Residual stress is best known to cause distortion of the metal component during machining. However, residual stress is also a key factor in other disastrous failure mechanisms in metal. In fact, residual stress is central to the properties of metal, including strength, fatigue life, machinability, and corrosion resistance.
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Still, residual stress is commonly accepted by the metal processing industry as the ‘known unknown’. In several industries such as automotive, aeronautics, oil and gas, and wind power, lifetime, operational reliability and product safety are paramount. In these particular industries, residual stress has been found to play an important role in the development of critical failure scenarios.
Improved production and products through Residual Stress Management
The Danish Technological Institute assists national and international companies in improving their production processes and products by managing residual stress in their materials. Typically, the company’s challenges will be solved through a four-step process:
- Problem clarification: Collection of information and data on the relevant material, its application, the operation conditions, etc. Based on this, measurable goals will be set up to ensure customer value creation.
- Inspection and analysis: Comprehensive investigation, measurement and analysis of the components and materials are performed using state-of-the-art analytical equipment.
- Mitigation – tests and treatment: Based on the information extracted in steps 1 and 2, mitigation strategies are designed and tested, including optimization of production parameters and posttreatment technologies such as heat treatment or shot-peening.
- Implementation: The suggested solution is implemented, commissioned and verified at the customer. Quality assurance systems are established to ensure long term effect of the solution.
By managing residual stress, companies can strengthen their competitive edge through:
- Lower safety factor requirements
- Improved productivity
- Reduced material waste and lower scrap rate
- Better products with reduced risk of failure
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Whether you are interested in residual stress measurement, stress relief technologies or how residual stress management can benefit your business, our specialists are ready to help you.