Synchrotron strain scanning for residual stress measurement in cold-drawn steel rods

Cold-drawn steel rods and wires retain significant residual stresses as a consequence of the manufacturing process. These residual stresses are known to be detrimental for the mechanical properties of the wires and their durability in aggressive environments. Steel makers are aware of the problem and have developed post-drawing processes to try and reduce the residual stresses on the wires. The present authors have studied this problem for a number of years and have performed a detailed characterization of the residual stress state inside cold-drawn rods, including both experimental and numerical techniques. High-energy synchrotron sources have been particularly useful for this research. The results have shown how residual stresses evolve as a consequence of cold-drawing and how they change with subsequent post-drawing treatments. The authors have been able to measure for the first time a complete residual strain profile along the diameter in both phases (ferrite and cementite) of a cold-drawn steel rod.

The role of residual stresses in the performance and durability of prestressing steel wires

Residual stresses developed during wire drawing influence the mechanical behavior and durability of steel wires used for prestressed concrete structures, particularly the shape of the stress–strain curve, stress relaxation losses, fatigue life, and environmental cracking susceptibility. The availability of general purpose finite element analysis tools and powerful diffraction techniques (X-rays and neutrons) has made it possible to predict and measure accurately residual stress fields in cold-drawn steel wires. Work carried out in this field in the past decade, shows the prospects and limitations of residual stress measurement, how the stress relaxation losses and environmentally-assisted cracking are correlated with the profile of residual stresses and how the performance of steel wires can be improved by modifying such a stress profile

Refuerzo de vigas de hormigón armado mediante la aplicación de fuerzas exteriores introducidas por predeformación de perfiles metálicos

Una técnica de refuerzo de elementos flectados en general y, en particular, de vigas y forjados de hormigón armado, consiste en la disposición de perfiles metálicos por debajo de los elementos a reforzar y retacados a ellos. En muchos casos este refuerzo se diseña con un planteamiento pasivo, es decir, los perfiles no entran en carga hasta que no se incrementan las acciones sobre el elemento reforzado, o lo hacen sólo ligeramente y de forma cuantitativamente no controlada efectuando el retacado mediante cuñas metálicas. En el presente trabajo se estudia la alternativa del refuerzo de vigas de hormigón armado frente a momentos flectores con un planteamiento activo, introduciendo unas fuerzas (por ejemplo, mediante gatos o barras roscadas) entre el perfil y el elemento a reforzar, y retacando posteriormente el perfil a la viga en los puntos de introducción de las fuerzas, mediante cuñas metálicas, mortero, etc. La propuesta que formulamos en el presente trabajo de investigación para el control de las fuerzas introducidas consiste en la medida de las flechas que se producen en el perfil metálico al hacerlo reaccionar contra la viga. Esto permite el empleo de procedimientos sencillos para la predeformación del perfil que no dispongan de dispositivos de medida de la carga introducida, o bien controlar la veracidad de las medidas de las fuerzas que dan tales dispositivos. La gran fiabilidad que tiene el cálculo de flechas en jácenas metálicas hace que con este procedimiento se puedan conocer con gran precisión las fuerzas introducidas. Las medidas de las flechas se pueden llevar a cabo mediante los procedimientos de instrumentación habituales en pruebas de carga, con una precisión más que suficiente para conocer y controlar con fiabilidad el valor de las fuerzas que el perfil ejerce sobre la viga. Los perfiles necesarios para el refuerzo con esta técnica son netamente inferiores a los que se precisarían con el planteamiento pasivo antes indicado. En el trabajo de investigación se recoge un estudio sobre el número, posición y valor de las fuerzas de refuerzo a introducir, en función de la carga para la que se diseña el refuerzo y la capacidad resistente del elemento a reforzar, y se analizan los valores máximos que pueden tener dichas fuerzas, en función de la capacidad de la pieza frente a momentos de signo contrario a los debidos a las cargas gravitatorias. A continuación se analiza la interacción viga-perfil al incrementarse las cargas sobre la viga desde el instante de la ejecución del refuerzo, interacción que hace variar el valor de las fuerzas que el perfil ejerce sobre la viga. Esta variación permite contar con un incremento en las fuerzas de refuerzo si, con las cargas permanentes presentes al reforzar, no podemos introducirlas inicialmente con el valor necesario, o si se producen pérdidas en las propias fuerzas. Este es uno de los criterios a la hora de seleccionar las características del perfil. Por el contrario, dicha variación puede suponer que en algunos puntos a lo largo del vano se supere la capacidad a flexión frente a momentos de signo contrario a los debidos a las cargas gravitatorias, lo que también debe ser tenido en cuenta. Seguidamente se analizan diferentes aspectos que producen una variación en el valor de las fuerzas de refuerzo, como son las deformaciones diferidas del hormigón (fluencia y retracción), los gradientes de temperatura en la pieza, o la actuación de sobrecargas en los vanos adyacentes. Se concluye los efectos de estos fenómenos, que en ocasiones tienen gran influencia, pueden ser cuantificados por el proyectista, recogiéndose propuestas sencillas para su consideración en casos habituales. Posteriormente recogemos una propuesta de metodología de comprobación del refuerzo, en cuanto a cómo considerar la fisuración y evolución del módulo de deformación de la viga, la introducción de la seguridad, la influencia de las tolerancias de laminación en el perfil sobre el valor calculado de las flechas necesarias en el perfil para introducir las fuerzas iniciales proyectadas, o la situación accidental de fuego, entre otros aspectos. Por último, se exponen las conclusiones más relevantes de la investigación realizada, y se proponen futuras líneas de investigación. One technique for strengthening flexural members in general, and reinforced concrete beams and slabs in particular, entails caulking the underside of these members with steel shapes. This sort of strengthening is often designed from a passive approach; i.e., until the load is increased, the shapes are either not loaded or are only slightly loaded to some unquantified extent by caulking with steel shims. The present study explored the possibility of actively strengthening the capacity of reinforced concrete beams to resist bending moments by applying forces (with jacks or threaded bars, for instance) between the shape and the member to be strengthened. The shape is subsequently caulked under the beam at the points where the forces are applied with steel shims, mortar or similar. The proposal put forward in the present study to monitor the forces applied consists in measuring the deflection on the steel shape as it reacts against the beam. With this technique, the shape can be pre-strained using simple procedures that do not call for devices to measure the force applied, or the accurancy of the respective measurements can be verified. As deflection calculations in steel girders are extremely reliable, the forces applied with this procedure can be very precisely determined. Standard instrumental procedures for load testing can be used to measure deflection with more than sufficient precision to reliably determine and monitor the value of the forces exerted on the beam by the shape. Moreover, the shapes required to strengthen members with this technique are substantially smaller than the ones needed in the aforementioned passive approach. This study addressed the number, position and value of the strengthening forces to be applied in terms of the load for which strengthening was designed and the bearing capacity of the member to be strengthened. The maximum value of such forces was also analysed as a function of the capacity of the member to resist counter-gravity moments. An analysis was then conducted of beam-shape interaction when the load on the beam raises since the instant that strengthening is applied, interaction that alters the forces applied to the beam by the shape. This variation can provide an increment in the forces if we cannot introduce them initially with the value calculated as necessary because they were limited by the permanent loads existing when strengthening, or if losses occur in the forces themselves. This is one of the criteria for defining shape specifications. Conversely, such variation may cause the forces to exceed beam counter-gravity bending strength at some points in the span, a development that must also be taken into consideration. Other factors inducing variations in the strengthening force values were then analysed, including deferred concrete strain (creep and shrinkage), temperature gradients in the member and the live loads acting on adjacent spans. The inference drawn was that these developments, which may on occasion have a heavy impact, can be quantified by the design engineer, particularly in ordinary situations, for which simple procedures are proposed. Methodology is likewise proposed for verifying strength in terms of how to appraise beam's cracking and variations in modulus of deformation; safety concerns; the effect of shape lamination tolerance on the calculated deflection necessary for the shape to apply the design forces; and fire-induced situations, among others. Lastly, the most prominent conclusions are discussed and future lines of research are suggested.

Pitting Corrosion in Austenitic Stainless Steel Water Tanks of Hotel Trains

The water storage tanks of hotel trains suffered pitting corrosion. To identify the cause, the tanks were subjected to a detailed metallographic study and the chemical composition of the austenitic stainless steels used in their construction was determined. Both the tank water and the corrosion products were further examined by physicochemical and microbiological testing. Corrosion was shown to be related to an incompatibility between the chloride content of the water and the base and filler metals of the tanks. These findings formed the basis of recommendations aimed at the prevention and control of corrosion in such tanks. Se han detectado problemas de corrosión por picaduras en los depósitos de agua de trenes hotel. Para identificar las causas se llevó a cabo un detallado estudio metalográfico así como de la composición química de los aceros inoxidables austeníticos utilizados en su construcción. También se realizaron estudios fisicoquímicos y microbiológicos de los productos de corrosión. Se ha encontrado que los problemas de corrosión están relacionados con la incompatibilidad entre el contenido en cloruros del agua y los metales base y de aporte de la soldadura de los tanques. En base a estos hallazgos se proponen una serie de recomendaciones encaminadas a la prevención y control de la corrosión de dichos depósitos.

Thermo-Mechanical Treatment Effects on Stress Relaxation and Hydrogen Embrittlement of Cold-Drawn Eutectoid Steels

The effects of the temperature and stretching levels used in the stress-relieving treatment of cold-drawn eutectoid steel wires are evaluated with the aim of improving the stress relaxation behavior and the resistance to hydrogen embrittlement. Five industrial treatments are studied, combining three temperatures (330, 400, and 460 °C) and three stretching levels (38, 50 and 64% of the rupture load). The change of the residual stress produced by the treatments is taken into consideration to account for the results. Surface residual stresses allow us to explain the time to failure in standard hydrogen embrittlement tests

Damage tolerance of cold drawn ferritic-austenitic stainless steels wires for prestressed concrete

Damage tolerance of high strength cold-drawn ferritic–austenitic stainless steel wires is assessed by means of tensile fracture tests of cracked wires. The fatigue crack is transversally propagated from the wire surface. The damage tolerance curve of the wires results from the empirical failure load when given as a function of crack depth. As a consequence of cold drawing, the wire microstructure is orientated along its longitudinal axis and anisotropic fracture behaviour is found at macrostructural level at the tensile failure of the cracked specimens. An in situ optical technique known as video image correlation VIC-2D is used to get an insight into this failure mechanism by tensile testing transversally fatigue cracked plane specimens extracted from the cold-drawn wires. Finally, the experimentally obtained damage tolerance curve of the cold-drawn ferritic–austenitic stainless steel wires is compared with that of an elementary plastic collapse model and existing data of two types of high strength eutectoid steel currently used as prestressing steel for concrete.

Computational Methods for Identification of Vibrating Structures

System identification deals with the problem of building mathematical models of dynamical systems based on observed data from the system" [1]. In the context of civil engineering, the system refers to a large scale structure such as a building, bridge, or an offshore structure, and identification mostly involves the determination of modal parameters (the natural frequencies, damping ratios, and mode shapes). This paper presents some modal identification results obtained using a state-of-the-art time domain system identification method (data-driven stochastic subspace algorithms [2]) applied to the output-only data measured in a steel arch bridge. First, a three dimensional finite element model was developed for the numerical analysis of the structure using ANSYS. Modal analysis was carried out and modal parameters were extracted in the frequency range of interest, 0-10 Hz. The results obtained from the finite element modal analysis were used to determine the location of the sensors. After that, ambient vibration tests were conducted during April 23-24, 2009. The response of the structure was measured using eight accelerometers. Two stations of three sensors were formed (triaxial stations). These sensors were held stationary for reference during the test. The two remaining sensors were placed at the different measurement points along the bridge deck, in which only vertical and transversal measurements were conducted (biaxial stations). Point estimate and interval estimate have been carried out in the state space model using these ambient vibration measurements. In the case of parametric models (like state space), the dynamic behaviour of a system is described using mathematical models. Then, mathematical relationships can be established between modal parameters and estimated point parameters (thus, it is common to use experimental modal analysis as a synonym for system identification). Stable modal parameters are found using a stabilization diagram. Furthermore, this paper proposes a method for assessing the precision of estimates of the parameters of state-space models (confidence interval). This approach employs the nonparametric bootstrap procedure [3] and is applied to subspace parameter estimation algorithm. Using bootstrap results, a plot similar to a stabilization diagram is developed. These graphics differentiate system modes from spurious noise modes for a given order system. Additionally, using the modal assurance criterion, the experimental modes obtained have been compared with those evaluated from a finite element analysis. A quite good agreement between numerical and experimental results is observed.

Effects of hydrogen assisted stress corrosion on damage tolerance of a high-strength duplex stainless steel wire for prestressing concrete

The study brings new insights on the hydrogen assisted stress corrosion on damage tolerance of a high-strength duplex stainless steel wire which concerns its potential use as active reinforcement for concrete prestressing. The adopted procedure was to experimentally state the effect of hydrogen on the damage tolerance of cylindrical smooth and precracked wire specimens exposed to stress corrosion cracking using the aggressive medium of the standard test developed by FIP (International Prestressing Federation). Stress corrosion testing, mechanical fracture tests and scanning electron microscopy analysis allowed the damage assessment, and explain the synergy between mechanical loading and environment action on the failure sequence of the wire. In presence of previous damage, hydrogen affects the wire behavior in a qualitative sense, consistently to the fracture anisotropy attributable to cold drawing, but it does not produce quantitative changes since the steel fully preserves its damage tolerance.