Quoted message said:Well, you are right that stress relieving will not make it "completely" stress free . See
lanl.govalum.htmlOpen ↗ , in that case the residual stresses were only 90%
relieved, which is about the best you can do with that type of aluminum alloy plate.
75mm thick annealed then 3% rolled aluminum plate and 2mm high tensile stainless wire are about as
similar as tomato & prime rib. the rib & tomato are both red & tasty, but the similarity ends there.
and, with respect, this whole debate seems to be confusing strain with stress. the example cited
describes /straining/ a sample that has a low percentage of cold work to a slightly higher
percentage in order to make the material uniformly strained throughout and thereby mitigate
distortion effects for machining precision aerospace components.
yes, the alloy block has measurable "stress" [elastic strain] due to it's non-uniformity, but it's
simply not possible to make a direct comparision between that most undoubtedly "macro" elastic
distortion and the profound microstrucure changes wrought on a wire that has been strained 100% or
more by pulling it through a die!
Quoted message said:Stresses are stored elastically in the crystal lattice. Under tensile stress, the lattice planes
are farther apart, etc. Basic elasticity. That is why x-ray and neutron diffraction can measure
residual stress by only measuring the lattice spacing without having to measure information about
dislocations.
correct. the measuring methods you describe will /only/ measure elastic stress, it's not a measure
dislocation density, the result of cold work.
but i still don't see where this argument is trying to go; the mechanical properties of the spoke,
particularly its fatigue characteristics, are the direct result of its composition, physical nature,
microstructure, dislocation density and its physical processing. every time i put a fatigued spoke's
fracture surface under the microscope and can see a crack initiating at a surface defect,
particularly when we're talking about a material that has *no* inherent fatigue endurance limit like
stainless steel, i have difficulty understanding why anyone would want to argue that plastically
straining the material further at this point is somehow going to make this crack initiator go away
or that its going to change a material's intrinic properties.
Quoted message said:When you anneal or thermally stress relieve a material you will reduce both stresses and
dislocations. But when you stress relieve by putting in uniform plastic deformation, you can
relive stress at the same time you increase cold work.
but we're not achieving uniform plastic deformation here. a 1% _strain_ on a 294mm spoke will take
it up to 297mm, unusable for it's original intent. there is no measurable plastic strain caused by
"stress relief" of a spoke. if you're talking local strain, that's a whole different ball of wax
from the 75mm plate example and if anything, small scale local strain is more likely to initiate
fatigue than mitigate it.
Quoted message said:There is a vast literature on stress relief BY cold work. They are most certainly not the
same thing.
that's the truth!
jb