Gerilmelerin Analizi ve Önlenmesi: Ölçüm Yöntemleri ve Nümerik Yaklaşım Uygulaması
12th International Aluminum Symposium, İstanbul, Türkiye, 18 - 20 Eylül 2025, ss.237-245, (Tam Metin Bildiri)
- Yayın Türü: Bildiri / Tam Metin Bildiri
- Basıldığı Şehir: İstanbul
- Basıldığı Ülke: Türkiye
- Sayfa Sayıları: ss.237-245
- Dokuz Eylül Üniversitesi Adresli: Evet
Özet
This study investigates the causes, measurement methods, and prevention strategies of residual stresses that arise during the production process of cast aluminum alloys. Residual stresses are elastic stresses that form within a material without any external load, typically after processes such as heat treatment, machining, or welding. These stresses directly affect the fatigue life, mechanical performance, and dimensional accuracy of components. In particular, rapid temperature changes during quenching in heat treatment processes like T6 can cause significant residual stresses. The study provides a detailed analysis of both destructive methods—such as hole drilling, ring core, and contour methods—and non-destructive techniques, including X-ray diffraction, ultrasonic testing, and neutron diffraction. The advantages and disadvantages of these methods are compared. In addition, analytical measurement methods based on finite element analysis (FEA) are also discussed. In recent years, analytical and numerical modeling techniques have been increasingly preferred due to the high fixture costs and setup complexity of other methods. The experimental part of this study involves numerical analyses, where residual stress values caused by temperature differences during various heat treatment steps were calculated and evaluated. Since whether these stresses are tensile or compressive directly impacts the fatigue life of a component, the importance of numerical analysis is once again emphasized. Furthermore, strategies to reduce these residual stresses are shared. Methods such as stress relief annealing, low-temperature aging, and surface treatments can help mitigate these stresses. In conclusion, the careful management of residual stresses contributes to the production of more durable and reliable engineering components. The numerical analysis results presented in this study offer valuable insights that can directly inform improvements in manufacturing processes.