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Journals / Dicle Üniversitesi Mühendislik Fakültesi Mühendislik Dergisi / 2025 / Cilt: 16 Sayı: 4

Review: Residual Stress Measurement Methods, Reasons and Prevention Studies in Aluminium Cast Alloys

İnceleme: Döküm Alüminyum Alaşımlarında Kalıntı Gerilme Ölçüm Yöntemleri, Nedenleri ve Önleme Çalışmaları

Onur Özaydin(DOKUZ EYLÜL ÜNİVERSİTESİ, FEN BİLİMLERİ ENSTİTÜSÜ, MAKİNE TEORİSİ VE DİNAMİĞİ (DR))0000-0001-6395-7553
Aytac Goren(DOKUZ EYLÜL ÜNİVERSİTESİ, MÜHENDİSLİK FAKÜLTESİ, MAKİNE MÜHENDİSLİĞİ BÖLÜMÜ, MAKİNE TEORİSİ VE DİNAMİĞİ ANABİLİM DALI)0000-0002-7954-1816
Esra Dokumacı(DOKUZ EYLÜL ÜNİVERSİTESİ, MÜHENDİSLİK FAKÜLTESİ, METALURJİ VE MALZEME MÜHENDİSLİĞİ BÖLÜMÜ, ÜRETİM METALURJİSİ ANABİLİM DALI)0000-0003-3886-3963
Gökçe Mehmet Gençer(DOKUZ EYLÜL ÜNİVERSİTESİ, MÜHENDİSLİK FAKÜLTESİ, MAKİNE MÜHENDİSLİĞİ BÖLÜMÜ, KONSTRÜKSİYON VE İMALAT ANABİLİM DALI)0000-0003-1084-7240
Pages
983–999
Publication Date
2025-12-30
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

In conclusion, managing residual stresses carefully is essential for producing more durable and reliable engineering components.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:This study investigates the causes, measurement methods, and prevention strategies of residual stresses occurring in cast aluminum alloys during the manufacturing process.
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Key Findings & Data:These stresses directly affect the fatigue life, mechanical performance, and dimensional accuracy of components.
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Conclusion & Impact:In conclusion, managing residual stresses carefully is essential for producing more durable and reliable engineering components.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Döküm Alüminyum Alaşımları · Kalıntı Gerilme · Tahribatlı ve Tahribatsız Ölçüm Yöntemleri.

Abstract

This study investigates the causes, measurement methods, and prevention strategies of residual stresses occurring in cast aluminum alloys during the manufacturing process. Residual stresses are elastic internal stresses that form in materials without any external load, typically due to processes like heat treatment, machining, or welding. These stresses directly affect the fatigue life, mechanical performance, and dimensional accuracy of components. In particular, sudden temperature changes during solution treatment and quenching in T6 heat treatment processes can lead to significant residual stresses. The study provides a detailed comparison of destructive methods (e.g., hole-drilling, ring-core, contour methods), non-destructive techniques (e.g., X-ray diffraction, ultrasonic testing, neutron diffraction), and analytical approaches using finite element modeling. The strengths and limitations of each method are discussed. In terms of fatigue performance, tensile residual stresses can be detrimental, while compressive stresses can enhance service life. Thus, accurate measurement and effective control of these stresses are crucial. Techniques such as stress relief annealing, low-temperature aging, and mechanical surface treatments are highlighted as effective in reducing residual stress. In conclusion, managing residual stresses carefully is essential for producing more durable and reliable engineering components.

Özet

Bu çalışma, döküm alüminyum alaşımlarında üretim sürecinde ortaya çıkan kalıntı gerilmelerin nedenlerini, ölçüm yöntemlerini ve önleme stratejilerini incelemektedir. Kalıntı gerilmeler; ısıl işlem, talaşlı imalat, kaynak gibi işlemlerden sonra, dış yük olmadan malzeme içinde oluşan elastik gerilmelerdir. Bu gerilmeler, parçanın yorulma ömrünü, mekanik performansını ve boyutsal doğruluğunu doğrudan etkiler. Özellikle T6 gibi ısıl işlem süreçlerinde, su verme sırasında meydana gelen ani sıcaklık değişimleri ciddi kalıntı gerilmeler yaratabilir. Çalışmada delik delme, halka çekirdek ve kontur gibi tahribatlı; X-ışını kırınımı, ultrasonik ve nötron kırınımı gibi tahribatsız yöntemler detaylı şekilde incelenmiş, bunların avantaj ve dezavantajları karşılaştırılmıştır. Ayrıca, sonlu elemanlar analizleriyle yapılan analitik ölçüm yöntemlerine de yer verilmiştir. Yorulma ömrü açısından, çeki kalıntı gerilmeleri zararlı olurken, bası gerilmeleri ömrü artırabilir. Bu nedenle kalıntı gerilmelerin ölçümü kadar kontrolü de önemlidir. Gerilme giderme tavlaması, düşük sıcaklıkta yaşlandırma ve yüzey işlemleri gibi yöntemlerle bu gerilmeler azaltılabilir. Sonuç olarak, kalıntı gerilmelerin dikkatli yönetimi, daha dayanıklı ve güvenilir mühendislik parçaları üretimini mümkün kılar.

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Cite This Article

Özaydin, O., Goren, A., Dokumacı, E., Gençer, G. M. (2025). Review: Residual Stress Measurement Methods, Reasons and Prevention Studies in Aluminium Cast Alloys. Dicle Üniversitesi Mühendislik Fakültesi Mühendislik Dergisi, Cilt: 16 Sayı: 4, 983–999. https://doi.org/10.24012/dumf.1697102

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