An ultrasonic technique for measuring stress in fasteners

High temperature bolting alloys are extensively used in the thermal power generation industry as for example, reheat ESV and Governor valve studs. Remnant life assessment methodologies and plant maintenance procedures require the monitoring of the operational stress levels in these fasteners. Some conventional ultrasonic techniques require longitudinal wave measurements to be undertaken when the nut on the bolt is loosened and then re-tightened. Other techniques use a combination of shear waves and longitudinal waves. In this paper, the problems and pitfalls associated with various ultrasonic techniques for measuring stress in bolts, is discussed. An ultrasonic technique developed for measuring the stress in Durehete 1055 bolts is presented. Material from a textured rolled bar has been used as a test bed in the development work. The technique uses shear wave birefringence and compression waves at several frequencies to measure texture, fastener length and the average stress. The technique was developed by making ultrasonic measurements on bolts tensioned in universal testing machines and a hydraulic nut. The ultrasonic measurements of residual stress have been checked against strain gauge measurements. The Durehete bolts have a hollow cylinder geometry of restricted dimensions, which significantly alters compression and shear wave velocities from bulk values and introduces hoop stresses which can be measured by rotating the polarization of the shear wave probe. Modelling of the experimental results has been undertaken using theories for the elastic wave propagation through waveguides. The dispersion equations allow the velocity and length of the fastener to be measured ultrasonically in some situations where the length of the fastener can not be measured directly with a vernier caliper or micrometer and/or where it is undesirable to loosen nuts to take calibration readings of the shear and compression wave velocities.