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4.1.1 Thermal quenching processes used with precipitation hardened aluminum alloy products can introduce significant residual stresses in the product. Mechanical stress relief procedures (stretching, compression) are commonly used to relieve these residual stresses in products with simple shapes. However, in the case of mill products with thick cross-sections (for example, heavy gage plate or large hand forgings) or complex shapes (for example, closed die forgings, complex open die forgings, stepped extrusions, castings), complete mechanical stress relief is not always possible. In other instances residual stresses may be unintentionally introduced into a product during fabrication operations such as straightening, forming, or welding operations.

4.1.2 Specimens taken from such products that contain residual stress will likewise themselves contain residual stress. While the act of specimen extraction in itself partially relieves and redistributes the pattern of original stress, the remaining magnitude can still be appreciable enough to cause significant error in the ensuing test result.

4.1.3 Residual stress is superimposed on the applied stress and results in an actual crack-tip stress intensity that is different from that based solely on externally applied forces or displacements.

4.1.4 Tests that utilize deep edge-notched specimens such as the compact tension C(T) are particularly sensitive to distortion during specimen machining when influential residual stress is present. In general, for those cases where such residual stresses are thermal quench induced, the resulting K_Ic or K_Q result is typically biased upward (that is, K_Q is higher than that which would have been achieved in a residual stress free specimen). The inflated values result from the combination of specimen distortion and bending moments caused by the redistribution of residual stress during specimen machining and excessive fatigue precrack from curvature5.

4.2.1 Provide warning signs that the measured value of K_Ic has been biased by residual stresses and may not be a lower limit value of fracture toughness.

4.2.2 Provide experimental methods by which to minimize the effect of residual stress on measured fracture toughness values.

4.2.3 Suggest methods that can be used to correct residual stress influenced values of fracture toughness to values that approximate a fracture toughness value representative of a test performed without residual stress bias.