Controlling the Residual Stress in Metallic Solids by Pulsed Electric Current

doi:10.11900/0412.1961.2021.00367

Acta Metall Sin

2022, Vol. 58

Issue (5): 581-598 DOI: 10.11900/0412.1961.2021.00367

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Controlling the Residual Stress in Metallic Solids by Pulsed Electric Current

ZHANG Xinfang¹(

), XIANG Siqi¹, YI Kun¹, GUO Jingdong²(

)

^1.School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China
^2.Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

ZHANG Xinfang, XIANG Siqi, YI Kun, GUO Jingdong. Controlling the Residual Stress in Metallic Solids by Pulsed Electric Current. Acta Metall Sin, 2022, 58(5): 581-598.

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Abstract

The generation of residual stress is unavoidable during the preparation and processing of metallic materials. This residual stress reduces the stability of material preparation and processing, particularly the surface tensile stress, which will reduce the fatigue and corrosion resistances of the material. Therefore, the effective regulation of the residual stress is generally required. However, traditional residual stress control methods, such as heat treatment, exhibits low efficiency because they are limited by material size and type. It is crucial to develop a new method for regulating residual stress that is green, low energy consumption, stable, effective, and applicable to various metallic materials. Pulsed electric current processing is a new material processing technology. It has been widely used in the elimination and control of residual stress in materials in the recent years. Herein, the generation, disadvantages, and traditional control methods of residual stress are briefly reviewed; the characteristics of residual stress under various pulsed electric current treatment modes are reviewed in detail; and the mechanism of residual stress under pulsed electric current is briefly discussed. Based on the obtained results, under the action of high energy pulsed electric current, the residual stress inside and on the surface of the metallic materials can be effectively eliminated in a very short period (approximately 1 s) and the maximum elimination rate can reach 100%. The higher the current density, the higher is the rate of residual stress elimination. Furthermore, the greater the initial residual stress in the material, it is simpler to eliminate residual stress. The experimental results of low energy continuous pulsed electric current treatment show that there are numerous types of response modes, such as increasing, decreasing, and unchanged residual stress, which are associated with the type of material and the pulse parameters. To control the residual stress in the material, the treatment method for coupling pulsed electric current and external stress is effective. Coupling low energy continuous pulsed electric current during material processing can effectively introduce residual compressive stress on the surface of the material and improve the fatigue and corrosion resistances of the material. The electrodynamic treatment technology, which produces hammering when the material is subjected to pulsed electric current, can transform the tensile stress on the material surface into compressive stress to improve the performance of the material. This effectively breaks through the high energy requirement of eliminating residual stress and allowing the workpiece directly in the setting regional area. Residual stress in pulsed electric current processing is removed via the following mechanism: Joule heating and pulsed electric current effects caused by pulsed electric current promote dislocation movement and reduce the flow stress of the material; therefore, the material can undergo plastic deformation at a low stress level, for which the pulsed electric current effect is crucial. The combined action of stress changes caused by pulsed electric current (thermal stress, pinch effect, magnetostrictive effect, and instantaneous thermal expansion stress), external stress (deformation and impact), and residual stress constitute the driving force to promote plastic deformation.

Key words: high energy pulsed electric current low energy continuous pulsed electric current residual stress electroplasticity multi-field coupling

Received: 30 August 2021

ZTFLH:

TF704.7

Fund: National Natural Science Foundation of China(U21B2082);National Natural Science Foundation of China(51874023);National Natural Science Foundation of China(U1860206);National Key Research and Development Program of China(2019YFC1908403);Fundamental Research Funds for the Central Universities(FRF-TP-20-04B)

About author: ZHANG Xinfang, professor, Tel: (010)62332265, E-mail: xfzhang@ustb.edu.cnGUO Jingdong, professor, Tel: (024)23971491, E-mail: jdguo@imr.ac.cn

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Fig.1 Residual stress classification at different scales^[3]

Fig.2 Typical waveform of high energy pulsed electric current oscillation attenuation wave^[29]

Fig.3 Relaxation of residual stress under pulsed electric current with different peak current densities (A, B, C, D, and E correspond to peak current densities of 0, 5.5, 6.0, 6.3, and 6.5 kA/mm²)^[24]

Fig.4 Evolution relationship of residual stresses in x direction (σ_x )(a) and y direction (σ_y ) (b) with processing time under high energy pulsed electric current multi-parameter (capacitor charging voltage) treatment (The x direction is parallel to the long axis of the sample, and the y direction is perpendicular to the axis of the sample)^[40]

Fig.5 The relationship between residual stress remove rate and initial residual stress under high energy pulsed electric current with different peak current densities (a), and linear relationship between peak current density and minimum residual stress that can be eliminated (b)

Fig.6 Relationship between residual stress and square root of dislocation density under different pulsed electric current parameters^[27]

Fig.7 Dislocation multiplication model under electroplastic effect^[27]
(a, b) Franke-Read dislocation multiplicatio models
(c-e) the models of dislocation multiplication under electron wind force
(f-h) the actual dislocation morphologies corresponding to models in Figs.7c-e, respectively

Fig.8 Square wave pattern of continuous pulsed electric current^[44] (Inset is a magnified view of a single pulsed electric current wave)

Fig.9 Residual stresses of welded joint of 16Mn steel and H08Mn2Si before and after single magnetic field treatment (M-T-1), single low energy continuous pulse current treatment (C-T-1), and magnetic field current coupling treatment (MC-T-1)^[28]

Fig.10 Residual stress reduction of 1080 steel with or without current at the same temperature. EPT1, EPT2, and EPT3 (the initial residual stresses were 361.3, 412.6, and 463.6 MPa, respectively) are pulsed electric current treatment with current density of 1.5 A/mm² for 1 h; HT1, HT2, and HT3 (the initial residual stresses were 435.3, 344.7, and 402.0 MPa, respectively) are heat trearment at 190^oC for 1 h; EPT4 (the initial residual stress was 442.4 MPa) is pulsed electric current treatment with current density of 2.8 A/mm² for 1 h; HT4 (the initial residual stress was 452.3 MPa) is heat treatment at 310^oC for 1 h

Fig.11 Surface treatment of low energy continuous pulsed electric current coupled ultrasonic material (EUIT—electropulsing assisted ultrasonic impact treatment)^[49]

Fig.12 Residual stress states on the surface of carbon steel treated by different methods (Utreated is the original state, UIT—ultrasonic impact treatment)^[49]

Fig.13 Schematic of electrodynamic device (a), physical drawings (b), and schematic of residual stress removal operation (c) (1—electrode, 2—casing, 3—disk, 4—inductance coil, 5—cover, 6 and 7—terminals, 8—induction coil,9—specimen, 10—assembly plate; C—capacitive energy storage, K—power switch, q—fixing load, ED—electrode device, SECP—source of electric current pulse)^[62]

Fig.14 Distribution of residual stress along line AA of AMg6 alloy welded plate after different treatment methods (Line 1 is the original state, line 2 is the residual stress distribution after single hammer treatment, and line 3 is the residual stress distribution after hammer coupled pulsed electric current treatment)^[62]

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