 RSM TM is an important component in the processes of  DESIGN,  MANUFACTURING,  MAINTENANCE and  REPAIR of PARTS and WELDED ELEMENTS RESIDUAL STRESS MANAGEMENT

IMPORTANCE OF RESIDUAL STRESS MANAGEMENT RESIDUAL STRESSES ORIGINATE FROM: Differential plastic flow Differential cooling rates Phase transformations with volume changes etc. RESIDUAL STRESSES ARE CREATED BY: Welding Machining Forging Rolling Surface treatments Casting Heat treatment WHERE RESIDUAL STRESSES ARE IMPORTANT: Fatigue Life Corrosion Resistance Dimensional Stability Brittle Fracture Distortion

STAGES IN RESIDUAL STRESS (RS) MANAGEMENT Stage 1: RS Determination MEASUREMENT: Destructive, Non-Destructive COMPUTATION Stage 2: RS Effect Analysis EXPERIMENTAL STUDIES COMPUTATION Stage 3: RS Modification (if required) CHANGES in TECHNOLOGY of MANUFACTORING / ASSEMBLY APPLICATION of STRESS - RELIEVING TECHNIQUES

RESIDUAL STRESS MANAGEMENT Proposed Complex of Advanced Engineering Tools Stage 1: RS Determination Stage 1: RS Determination Ultrasonic Measurement of Applied and Residual Stresses Device and Software – UltraMARS TM Stage 2: RS Effect Analysis Stage 2: RS Effect Analysis Expert System for Fatigue Assessment and Optimization of Parts and Welded Elements - RESIsT TM Stage 3: RS Modification (if required) Stage 3: RS Modification (if required) Ultrasonic Peening of Parts and Welded Elements Equipment and Software – UltraPeen TM

RESIDUAL STRESS MANAGEMENT Ultrasonic Measurement of Applied and Residual Stresses Measurement Unit Laptop Measurement Unit with Transducers Supporting Software Expert System for Residual Stress Analysis Advanced database and analysis of the influence of residual stresses on the fatigue life of parts and welded elements Computerized complex - UltraMARS TM

RESIDUAL STRESS MANAGEMENT Expert System for Fatigue Assessment and Optimization of Parts and Welded Elements RESIsT TM The RESIsT TM is an Expert System for optimization of welded elements and structures by fatigue criterion. The following important parameters of welded structures with the goal to enhance the fatigue performance are analyzed:  preferred design of parts and welded elements;  material selection;  welding and other technological processes;  residual stresses;  application of improvement treatments;  influence of possible repair technologies;  realistic service conditions.

RESIDUAL STRESS MANAGEMENT Ultrasonic Peening of Parts and Welded Elements ● Piezoelectric transducer with a set of heads for different applications: weight: ~2 kg, length: ~420 mm ● Ultrasonic generator: weight: ~ 4.5 kg dimensions: 350x250x90 mm ● Output frequency: 20 kHz ● Power supply: 250 – 500 watts Ultrasonic Transducer and Generator ● Optimization of the UP application parameters: maximum possible increase in fatigue life of parts and welded elements with minimum cost, labor- and power- consumption ● Quality monitoring of UP process ● Fatigue assessment of welded elements after UP Software

RESIDUAL STRESS MANAGEMENT Distribution of residual stresses 1 and 2 - before and after application of the improvement treatment Fatigue curves of fillet welded joint 1 -  r = 240 MPa (Δ  = 85 MPa); 2 -  r = -10 MPa (Δ  = 123 MPa); 3 -  r = 40 MPa; 4 -  r = -60 MPa Measurement of Residual Stresses, Fatigue Assessment and Improvement Treatment of Welded Element Result: 4 times increase in fatigue life

INTERACTION OF SOFTWARE AND HARDWARE SOFTWARE ULTRAPEEN UP Optimum Application and Remote Control SOFTWARE ULTRAMARS Advanced Database and Residual Stress Analysis EXPERT SYSTEM RESIST Fatigue Assessment And Optimization of Welded Elements WELDED ELEMENTS DEVICE ULTRAPEEN Ultrasonic Peening of Parts and Welded Elements DEVICE ULTRAMARS Ultrasonic Measurement Of Applied and Residual Stresses WELDED ELEMENTS with Enhanced Fatigue Performance, Corrosion Resistance, Dimensional Stability and Reduced Distortions