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THERMAL TREATMENT
ABSTRACT
In an introductory review, the techniques and equipment for vibratory stress re/eving are
described and app/ications exemplified with case histories. lt has been proven that the
process gives stablisation results comparable with and in many cases exceedng those
obtained wth therma/ treatment, whlst be;ng quicker, cheaper, more versatife as the
equipment is complete/y portable and the technique offers many advantages when machined
parts or heavy fabrications are in volved.
INTRODUCTION
Over the last 60 years, vibratory stress relieving
has evolved from a little known art into an
indispensable basic process, which is now a well
tried and established alternative to thermal
treatment for the treatment of castings,
fabrications,
components
reqUinng
intricate
machining operations and non-ferrous metals. lt is
important to emphasize that vibratory stress
relieving is not claimed to be a substitute for all
thermal t reatments although there is sorne
common ground just as there are areas where each
process is and will remain predominant.
Therma l and Vibratory treatment share a capabi lity
in three areas, namely overall stress reduction,
dimensional control and dimensional stabi lisation.
Although total stress relief is almost impossible to
obtain by using any commercial process, vibratory
stress relieving can stabilise and stress relieve the
component at any stage of the manufacturing or
machining process without changing the materials
metallurgical condition, without scaling or
discoloration and without distortion at low cost and
with minimal time restraints to the manufacturer.
Conversely on ly thermal treatment will change a
material's metallurgical properties and thermal
treatment is also more effective than vibratory
stress relieving when used to prevent incidences of
brittle fracture, although more often correct
material selection is a prerequisite for the
prevention of this type of fai lure.
Additionally, materials that derive their mechanical
properties from transformation hardening or cold
working cannot be so thoroughly stabilised. Thus
the complementary nature of the two processes
can be appreciated. However instability in these
types of materials can be successfully treated
using vibratory stress relieving. The vibratory
process involves inducing metal structures into one
or more resonant and sub resonant cond itions
usinq oortable hioh force exciters. Treatment
periods are short and frequencies generally in the
range l0-230Hz.
PAST RESEARCH
lt is possible to f ind technical papers, ostensibly
written about vibratory stress relieving dating as
far back as 1934, but in fact, there have been few
genuine research programs into the process.
The bulk of the papers concern either general
oscillatory testing of metals or work which the
author thought to be related to vibratory stress
relievinq without prooerlv evaluatinc and
appreciating the process. Many tests were limited
to simple test bars. which due to restricted
RESONANT VSR
This has evolved over a 40-year period. For the
VCM series mid 1997 saw major research-led
changes in both approach and equipment
specification. In well defined areas of application.
R-VSR is now 100% successful in its rnain
objective stress relief-component stabilisation.
The treatrnent of components from less than 1kg
to in excess of 100 ton is cornmonplace .
Procedures stipulate a progression up the peaks
to resonance, consisting of a pause at the foot to
allow any crit ically high stresses to diminish, prior
to treating at the mid height region and then a
short defined number of cycles at the actual
peak. As long as the mean stress is allowed to
float the resulting cyclic imposed, strans
progressively add to the residual strains in the
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INDUSTRIAL EXAMPLES
The widespread use of, and the general
satisfaction with vibratory stress relieving has
been shown by the extent to which it has been
accepted by virtually all sectors of industry; so
extensive in fact t hat it is impossible to tru ly
represent the entire spectrum here.
No specific example of mild steel fabrications or
cast iron 1 cast steel castings is given here as it is
well accepted that where no metallurgical
changes are requ ired, vibratory stress relievi ng is
as good as therma l stress relieving for stabilising
and stress relieving beams, bases, columns,
gearboxes, bedplates etc.
But it is quicker, cleaner and cheaper as
witnessed by thousands of regular users over t he
last 45 years in virtually every applicable
englneering field. The acceptance and usage of
VSR in South Africa alone has increased by an
average of 69% annually since 1992.
Courtesy Rotary Ma
South A frica
Gearbox Casinqs
(g) Typically,
screens
are
mild-steel
fabrications from 1m x 3m to 3m x 10m
and 100 to 200mm deep - usually a
complex lattice of RHS, angle and tubular
members. lf thermally stress relieved,
they usually distort badly and need
mechanical or thermal straightening, often
defeating the object of the original
thermal treatment. When no stress relief
or thermal treatment was used, butt welds
that lacked preparation and had their
bead ground off, leaving a weak joint,
failed in service. Now, with the
introduction of VSRP, welders know that a
poor joint will break in the weld shop so
they ensure good joints. This 'fitness for
purpose' testing is regarded by Goodwin
Barsby, Parker, Kue Ken, Pegsons,
Babcock Power, etc. as a good reason to
use the VSRP, as in-service life has, on
average, tripled.
(h) Beams, Sm long x 140 x 300mm section,
fabricated from RTQ60 material, bowed
2mm during rough machining. Thermal
stress relieving was not permissible on
metallurgical grounds. The VSRP has
completely solved the problem for British
Steel.
carpet knife blades. These are typical ly mildsteel bar, 5m x 150 x lOmm, grooved out and
deposited with stellite along one long edge.
Th is edge is ground to expose the stellite and
form a cutting edge. The mild-steel section
behind is slotted to give adjustments for the
holding screws. Up to ten year ago, it was
common for 50% of t he wear tolerance to be
lost due to movement taking place duri ng
t ransport (typica lly UK to ltaly). Since
introducing the VSRP, no movement has
and
t ighter tolerances
are
occu rred
maintained.
Hundreds of examples are on file: large copper
plates fully machined, screwed and dowelled;
flow-brazed
aluminum
instrument
frames;
powder-coated enameled 25mm x 25mm mildsteel angle instrument frames for Marconi;
mixed-metal fabrications for Helio tank turrets
and a wide variety of materials such as Jnconel,
Zeron, duplex stainless steel, Ferraliu, titanium,
P20 (l. 7% Cr steel), alum inum in TF condition,
composite metal 1 plastic, metal 1 rubber
fabricati ons, etc. for these and many other
applications, the VSRP is invaluable.
However, it must be remembered that the VSRP
cannot be used on pressure vessels, pipework or
any parts where metallurgical change is
necessary. To its benefit VSRP can be used on all
non-ferrous materials and on the hardened
materials that are commonplace on most mining
and quarrying components. No reduction or
softening of material properties occur with the
correct treatment
Treatment of La
CONCLUSIONS
Based on hitherto attained research resu lts and
experience in practica! use of VSR weldments the
introduction of VSR into practice can be
recommended . The Vibratory stress relieving can
be employed for stabilisation of the size of
suitable weldments prior to their machining and
servicing as a replacement of stress relief
annealing. The VSR process is used for lowering
of residual stresses and stabilisation of the size of
different weldments such as trames of forming
machines, machine trames, grey cast iron
casti ngs, etc. which were up to now subjected to
stress relief annealing.
VSR does not negatively affect the static dynamic
strength of welded joints and weldments, fracture
and notch toughness and homogeneity of welded
joints.
Based
on
the
attained
data
the
implement ation of VSR procedures as a
replacement of stress relief annealing for
the stabilisation of weldments, castings and
forging leads to high savings of production
costs to our national economy. The saving