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RSM TM is an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and

RESIDUAL STRESS MANAGEMENT. RSM TM is an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and REPAIR of PARTS and WELDED ELEMENTS. IMPORTANCE OF RESIDUAL STRESS MANAGEMENT. RESIDUAL STRESSES ORIGINATE FROM:

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RSM TM is an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and

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  1. RESIDUAL STRESS MANAGEMENT RSMTMis an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and REPAIR of PARTS and WELDED ELEMENTS

  2. 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

  3. 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

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

  5. RESIDUAL STRESS MANAGEMENT Ultrasonic Measurement of Applied and Residual Stresses Computerized complex - UltraMARSTM Laptop Measurement Unit • 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 • Measurement Unit with Transducers • Supporting Software

  6. RESIDUAL STRESS MANAGEMENT Expert Systemfor Fatigue Assessment and Optimizationof Parts and Welded Elements RESIsTTM The RESIsTTMis 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.

  7. RESIDUAL STRESS MANAGEMENT Ultrasonic Peening of Parts and Welded Elements Ultrasonic Transducer and Generator Software ● 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 ● 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

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

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

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