Time transient validation of residual stress prediction models for aluminium alloy quenching

Finite element models that predict residual stress states in relatively large quenched aluminium alloy products tend to give reliable results. However, even though there is confidence that the predicted stress state is correct, there is no validation indicating that the stress/displacement development during the quench is comparable to the experimental case. Combined with this, finite element predictions for small samples tend to underestimate surface stress. This paper uses a ‘Navy C-Ring’ benchmark design to monitor displacement during quenching. The heat transfer coefficient is found to be the most dominant boundary condition and is critical to ensuring displacement and residual stress predictions that match the experimental case. This paper is part of a Themed Issue on Measurement, modelling and mitigation of residual stress.