X-ray diffraction analysis of the residual stresses in aluminum alloys for automotive manufacturing

The influence of thermal treatment on mechanical stress state of Al alloy samples and cylinder head have been study by X ray diffraction. The experimental difficulties produced by an important grain size of the alloys led us to the optimization of the parameters of the X ray diffraction setup. The systematic study of the factors influence would imply a prohibitive number of experiments, whereas the methodology of Taguchi experiment plans allows a definition of each factor role and of optional conditions of the X ray diffraction setup with a very low number of experiments. Then the minimization of the uncertainty on stress results has been reached. In the case of cylinder head, after quench, the stress state is heterogeneous (-100MPa < sigma < 0MPa) and a strong anisotropy is evidenced. The thermal annealing generates an homogenization of the stress state and a decreasing of its amplitude. This is in good accordance with the results obtained from the thermo-mechanical model used.