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Chapter 11: Problem 20

Cite three sources of internal residual stresses in metal components. What are two possible adverse consequences of these stresses?

Short Answer

Expert verified
Answer: The three sources of internal residual stresses in metal components are quenching, welding, and cold working. Two possible adverse consequences of these stresses are distortion and stress corrosion cracking.

Step by step solution

01

Source 1: Quenching

Quenching is a rapid cooling process used to harden metals such as steel by immersing them in a cooling medium like water or oil. The rapid cooling produces non-uniform temperature distribution and varying phase transformations in the material, leading to local misfits and creating internal residual stresses.
02

Source 2: Welding

Welding causes residual stresses due to the localized heating and cooling of the material at the weld joint. As the welded material cools and contracts, different phases of the metal undergo varying thermal expansion and contraction, causing residual stresses that may lead to distortion or even failure, especially if multiple welds are applied without stress relief steps.
03

Source 3: Cold working

Cold working is the process of plastic deformation of a metal at low temperatures. This plastic deformation causes an increase in dislocation density, which, in turn, causes lattice strain, resulting in internal residual stresses within the metal component. Now, let's analyze the two possible adverse consequences of these residual stresses.
04

Adverse Consequence 1: Distortion

The development of internal residual stresses can cause distortion, leading to dimensional inaccuracy in the final product. This may require additional machining steps or rejection of the component due to the impossibility of meeting dimensional tolerances, increasing production costs and time.
05

Adverse Consequence 2: Stress Corrosion Cracking

Internal residual stresses may lead to stress corrosion cracking (SCC), which is a type of corrosion that occurs when a susceptible material is exposed to a corrosive environment under tensile stress. SCC can result in the premature failure of the metal component, causing safety concerns and expensive repair or replacement costs.

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