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  2. Dr Foroogh Hosseinzadeh

Dr Foroogh Hosseinzadeh

Profile summary

Professional biography

I completed my BSc and MSc degrees in Mechanical Engineering and received my PhD on residual stresses in shrink fits in 2009 from the University of Bristol. I then joined the Materials Engineering Group at the Open University (OU) and was appointed as the lead researcher for a £1m “Contour Method Research Programme” funded by EMDA (East Midland Development Agency), Rolls Royce, LIoyd’s Register Foundation and the OU. In 2012 I was appointed lecturer and promoted to Senior lecturer in 2016. 

Research interests

Experimental methods, structural integrity, residual stress and in particular developing multi-scale hybrid measurement methods to facilitate stress engineering for industrial applications.

Teaching interests

I have contributed to the production and presenatation of several modules including:

1- T193 Engineering: Frameworks, Analysis

2- T272 Core Engineering B

3- T276 Engineering: professions, practice and skills 2

4- T805 Manufacture materials design

Externally funded projects

Near-to-surface (100 space micron) residual stresses
RoleStart dateEnd dateFunding source
Lead01 May 202030 Apr 2023Rolls-Royce Submarines Ltd

The manufacturing processes used to make high performance parts for structures and systems inherently introduce locked-in residual stresses at both the macro-scale and micro-scale. In particular surface machining and modification operations create near-to-surface residual stress distributions that have high gradients associated with intense work hardening and/or local phase transformation effects. The aim of the proposed PhD project is to develop improved measurement systems that can quantify near-to-surface (up to 100 microns) residual stresses in manufactured components with high certainty.

RCUK Catapult Researchers in Residence (HVM AFRC- NAMRC- AMRC- Digital) - An Accessible Residual Stress Prediction Tool for High Value Components
RoleStart dateEnd dateFunding source
Lead01 Apr 201931 Aug 2022EPSRC Engineering and Physical Sciences Research Council

Manufacturing processes often introduce locked-in stresses, namely residual stresses, in the fabricated parts. They could cause distortion and cracking, influence performance, reduce products lifetime leading to premature failure and result in lower productivity. In high value manufacturing it is of paramount importance to characterise the state of residual stress in manufactured parts. However, residual stresses are notoriously difficult to characterise. Prediction of residual stresses requires sophisticated advanced computer modelling that are often time consuming and the reliability of predictions depends on the expertise of the modeller and input data. Experimental characterisation of residual stresses require access to measurement techniques, expertise or central facilities. Often multiple residual stress measurement techniques are required to unlock useful information. They can be costly, time consuming, difficult to implement due to the nature of the component or limitation of available techniques. A neural network model was developed at the Open University and applied to predict residual stress profiles in austenitic stainless steel pipe girth welds. This project proposes to further develop the neural network approach and implement it to other manufacturing processes. It will provide the manufacturing catapults and industrial end users a readily accessible tool for prediction of residual stresses in manufactured parts without the need to get access to central facilities, measurement equipment, expertise or expensive computational modelling. It can be used as a user-friendly decision making tool to design manufacturing process parameters with a view to introduced controlled level of residual stress. This will be of great value for high value manufacturing.

EPSRC Centre For Doctoral Training (CDT) - Nuclear Energy
RoleStart dateEnd dateFunding source
Co-investigator01 Apr 201930 Sep 2027EPSRC Engineering and Physical Sciences Research Council

An existing CDT led by the Centre for Nuclear Engineering (CNE) at Imperial College in collaboration with multi-disciplinary nuclear groups at Cambridge (Nuclear Energy Centre, CNEC) and The Open Universities, is now joined by the University of Bristol and Bangor University to form a new Nuclear CDT, bringing together over 50 academics with internationally-leading research across nuclear materials (e.g. primary circuit structures, fuels, structural materials and wasteforms), joining/manufacturing technologies, structural integrity assessment methods and standards, thermal hydraulics, geological storage and disposal (e.g. rock mechanics), safety and security (e.g. accident modelling and structural integrity), nuclear technology policy and public engagement, plant decommissioning and clean up, regulation, new nuclear build, advanced reactor technology, the fuel cycle, plant life extension, and naval nuclear propulsion.

The Contour Method for Composite Materials
RoleStart dateEnd dateFunding source
Lead07 Jan 201906 Jan 2022CETIM Centre Technique Des Industrie Mechaniques

The contour method is one of the most recently developed techniques for measurement of residual stress. The contour method is performed in four stages: (i) the component is sectioned in two halves along a plane of interest using electric discharge machining, (ii) the resulting out of plane displacement of the created cut surfaces caused by the relaxation of residual stresses is measured often using a Coordinate Measuring Machine (CMM) fitted with a touch probe or an optical sensor, (iii) the measured out of plane displacements are processed to remove the effect of shear stress and artefacts introduced due to the wire EDM process or surface measurement, (iv) the processed data are used as surface boundary conditions to a Finite Element (FE) model of one of the cut parts and fully elastic stress analysis is performed to back calculate the original and pre-cut state of residual stress. An outstanding advantage of the contour method compared to other strain relief and diffraction based techniques is that it can provide a cross-sectional map of residual stress using readily available equipment in most workshops. In theory the ability of the technique in measuring through thickness residual stresses is not limited by the size or geometrical complexity of components. Although only one component of the stress tensor, perpendicular to the cut surface, can be measured using one single contour cut, the technique has been expanded to measure multiple components of the stress tensor when combined with other techniques or multiple cuts used. In addition unlike diffraction based techniques the contour method is not sensitive to microstructural variations that is often observed in weldments. The contour method, however, has been mainly applied to measure residual stresses in metals, homogeneous and isotropic materials. The challenge of this research project is to develop the technique to measure residual stresses in inhomogeneous, anisotropic and electrically non-conductive materials such as composites.

Advanced Tools for structuraL integrity Assessment and Plant Lifetime management
RoleStart dateEnd dateFunding source
Lead01 Jun 201730 Nov 2021EC (European Commission): FP (inc. Horizon Europe, H2020, ERC)

This is a Horizon 2020 project proposal. The consortium comprises 19 EU participants: 9 represent research institutions, 5 represent academia, 4 represent industry and one represents a regulatory authority. A systematic ageing management procedure is the basis for justifying the safe long term operation of nuclear power plants. One fundamental part in this process is to demonstrate the integrity of the nuclear power plant components. The required safety margins are determined by considering various degradation and ageing mechanisms and postulated defects. This project focuses on identified open technology gaps related to piping components. OU Contributions relate to WP2 which is concerned with the simulation, measurement and treatment of residual stress.

Complex Contour Method
RoleStart dateEnd dateFunding source
Lead01 Mar 201531 Jul 2017EPSRC Engineering and Physical Sciences Research Council

The safe operation of engineering structures is vital in safety critical industries. Structural integrity failures can have catastrophic consequences in terms of loss of life and financial circumstances. Meanwhile there is a strong interest in reducing costs, light-weighting, increasing design life and life extension. To this end reliable structural assessments are essential at the design stage and through in-service life to ensure continuous profitable operation of assets. Residual stresses are inevitably introduced in engineering structures during manufacturing processes. Their presence can have adverse effects on the behaviour of structures and contribute to driving force promoting degradation mechanisms including crack initiation, crack growth, stress corrosion cracking, fatigue and fracture. Therefore it is of paramount importance that the state of residual stresses in engineering structures is carefully and reliably characterised so that remedial actions could be taken to enhance the lifetime of current materials or novel designs and manufacturing methods developed and optimised. For the first time, this project proposes novel advances that will radically bring new capabilities for the contour method of residual stress measurement in several ways: it will unlock maps of residual stress in multiple directions simultaneously. Of a true step change is extending the application of the technique to measure 3D maps of residual stress. The application of novel advances enables the technique to be implemented on complex engineering structures. The proposed research has the potential to provide far more complete residual stress information about safety critical components of high interest to engineers in the aerospace, petrochemical, power generation and nuclear industries.

Publications

The incremental contour method using asymmetric stiffness cuts (2021-01-01)
Achouri, Anas; Hosseinzadeh, Foroogh; Bouchard, P. John; Paddea, Sanjooram and Muransky, Ondrej
Materials and Design, 197, Article 109268


Mitigating Cutting-Induced Plasticity Errors in the Determination of Residual Stress at Cold Expanded Holes Using the Contour Method (2021)
Kim, H.K.; Carlson, S. S.; Stanfield, M. L.; Paddea, Sanjooram; Hosseinzadeh, F. and Bouchard, P. J.
Experimental Mechanics ((Early access))


Residual Stresses Measurement in Hollow Samples Using Contour Method (2020-05)
Mahmoudi, A.H.; Yoosef-Zadeh, D. and Hosseinzadeh, F.
IJE Transactions B: Applications, 33(5) (pp. 885-893)


Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components (2019-08-01)
Ali, Haider; Ghadbeigi, Hassan; Hosseinzadeh, Foroogh; de Oliveira, Jeferson and Mumtaz, Kamran
The International Journal of Advanced Manufacturing Technology, 103(9-12) (pp. 4467-4479)


Redistribution of residual stress by thermal shock in reactor pressure vessel steel clad with nickel alloy (2019-01)
Oliver, Sam J.; Mostafavi, Mahmoud; Hosseinzadeh, Foroogh and Pavier, Martyn J.
International Journal of Pressure Vessels and Piping, 169 (pp. 37-47)


Investigating optimal cutting configurations for the contour method of weld residual stress measurement (2018-07)
Muránsky, O.; Hosseinzadeh, F.; Hamelin, C.J.; Traore, Y. and Bendeich, P.J.
International Journal of Pressure Vessels and Piping, 164 (pp. 55-67)


Evaluation of a self-equilibrium cutting strategy for the contour method of residual stress measurement (2018-07)
Muránsky, O.; Hamelin, C. J.; Hosseinzadeh, F. and Prime, M. B.
International Journal of Pressure Vessels and Piping, 164 (pp. 22-31)


Residual stress measurement round robin on an electron beam welded joint between austenitic stainless steel 316L(N) and ferritic steel P91 (2017-07)
Javadi, Y.; Smith, M.C.; Abburi Venkata, K.; Naveed, N.; Forsey, A.N.; Francis, J.A.; Ainsworth, R.A.; Truman, C.E.; Smith, D.J.; Hosseinzadeh, F.; Gungor, S.; Bouchard, P. J.; Dey, H.C.; Bhaduri, A.K. and Mahadevan, S.
International Journal of Pressure Vessels and Piping, 154 (pp. 41-57)


Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method (2017-06)
Sun, Y. L.; Roy, M. J.; Vasileiou, A. N.; Smith, M. C.; Francis, J. A. and Hosseinzadeh, F.
Experimental Mechanics, 57(5) (pp. 719-734)


Quantification of Residual Stresses in Electron Beam Welded Fracture Mechanics Specimens (2017-02)
Kapadia, Priyesh; Davies, Catrin; Pirling, Thilo; Hofmann, Michael; Wimpory, Robert; Hosseinzadeh, Foroogh; Dean, David and Nikbin, Kamran
International Journal of Solids and Structures, 106-107 (pp. 106-118)


Mitigating cutting-induced plasticity in the contour method, part 1: Experimental (2016-09)
Hosseinzadeh, F.; Traore, Y.; Bouchard, P. J. and Muransky, O.
International Journal of Solids and Structures, 94-95 (pp. 247-253)


Mitigating Cutting-Induced Plasticity in the Contour Method, Part 2: Numerical Analysis (2016-09)
Muransky, O.; Hamelin, C. J.; Hosseinzadeh, F. and Prime, M. B.
International Journal of Solids and Structures, 94-95 (pp. 254-262)


Measurement and prediction of residual stresses in quenched stainless steel components (2014-09)
Hosseinzadeh, F.; Hossain, S.; Truman, C. E. and Smith, D. J.
Experimental Mechanics, 54(7) (pp. 1151-1162)


Towards good practice guidelines for the contour method of residual stress measurement (2014-08-27)
Hosseinzadeh, Foroogh; Kowal, Jan and Bouchard, Peter John
Journal of Engineering ((Online only))


Plasticity in the contour method of residual stress measurement (2014-08-01)
Traore, Yeli; Hosseinzadeh, Foroogh and Bouchard, P. John
Advanced Materials Research, 996 (pp. 337-342)


Numerical analysis of retained residual stresses in C(T) specimen extracted from a multi-pass austenitic weld and their effect on crack growth (2014-08)
Muránsky, O.; Bendeich, P. J.; Smith, M. C.; Hosseinzadeh, F. and Edwards, L.
Engineering Fracture Mechanics, 126 (pp. 40-53)


Controlling the cut in contour residual stress measurements of electron beam welded Ti-6Al-4V alloy plates (2013-06)
Hosseinzadh Torknezhad, F.; Ledgard, P. and Bouchard, P. J.
Experimental Mechanics, 53(5) (pp. 829-839)


Mapping multiple components of the residual stress tensor in a large P91 steel pipe girth weld using a single contour cut (2013-02)
Hosseinzadeh, F. and Bouchard, P. J.
Experimental Mechanics, 53(2) (pp. 171-181)


Mapping multiple components of the stress tensor using the contour method (2013)
Hosseinzadeh, Foroogh and Bouchard, Peter John
Materials Science Forum, 768-769 (pp. 87-94)


Slitting and Contour Method Residual Stress Measurements in an Edge Welded Beam (2012-02)
Hosseinzadh, Foroogh; Toparli, Muhammed Burak and Bouchard, Peter John
Journal of Pressure Vessel Technology, 134(1) (pp. 011402-1-011402-6)


Application of deep hole drilling to the measurement and analysis of residual stresses in steel shrink fitted assemblies (2011-12)
Hosseinzadeh, F.; Mahmoudi, A. H.; Truman, C. E. and Smith, D. J.
Strain, 47(S2) (pp. 412-426)


Measurements of Residual Stress in a Welded Compact Tension Specimen Using the Neutron Diffraction and Slitting Techniques (2010)
Hosseinzadh, Foroogh; Bouchard, P. John and James, Jonathan A.
Materials Science Forum, 652 (pp. 210-215)


Through thickness residual stresses in large rolls and sleeves for metal working industry (2009-07)
Hosseinzadeh, F.; Smith, D. J. and Truman, C. E.
Materials Science and Technology, 25(7) (pp. 862-873)


Experimental evaluation of the effect of residual stress field on crack growth behaviour in CT specimen (2006-09)
Farrahi, G. H.; Majzoobi, G. H.; Hosseinzadeh, F. and Harati, S. M.
Engineering Fracture Mechanics, 73(13) (pp. 1772-1782)


Standardisation on Measurement and Interpretation of Residual Stress Data (2019)
Mirzaee-Sisan, Ali; Bouchard, P. John and Hosseinzadeh, Foroogh
In : OAME 2019 38th International Conference on Ocean, Offshore and Arctic Engineering (9-14 Jun 2019, Glasgow, Scotland)


Should Residual Stresses Be Taken Into Account in Structural Integrity Assessment of Offshore Monopiles? (2018-06-17)
Jacob, Anais; de Oliveira, Jeferson Araujo; Mehmanparast, Ali; Hosseinzadeh, Foroogh and Berto, Filippo
In : ASME 2018 37th International Conference on Ocean, Offshore and Arctic Engineering (17-22 Jun 2018, Madrid, Spain)


Asymmetric Cuts In The Contour Method For Residual Stress Measurement (2017-06-12)
Achouri, A.; Bouchard, P. J.; Kabra, S. and Hosseinzadeh, F.
In : 7th International Conference on Mechanics and Materials in Design, (11-15 Jun 2017, Albufeira/Portugal) (pp. 1177-1178)


Residual stress measurement of a hipped bonded valve seat using the contour method (2013)
Hosseinzadeh, Foroogh and Bouchard, P. John
In : ASME 2013 Pressure Vessels and Piping Conference (14-18 Jul 2013, Paris)


Residual stress measurement in a stainless steel clad ferritic plate using the contour method (2013)
Naveed, Nida; Hosseinzadeh, Foroogh and Kowal, Jan
In : ASME 2013 Pressure Vessels and Piping Conference (14-18 Jul 2013)


Making the cut for the contour method (2012-07)
Bouchard, P. John; Ledgard, Peter; Hiller, Stan and Hosseinzadh Torknezhad, Foroogh
In : 15th International Conference on Experimental Mechanics (22-27 Jul 2012, Porto, Portugal)


Residual stress measurement of a ferritic bead on plate benchmark test specimen using the contour method (2012)
Hosseinzadeh, Foroogh and Bouchard, P. John
In : ASME 2012 Pressure Vessels and Piping Conference (15-19 Jul 2012, Toronto)


Application of the contour method to validate residual stress predictions (2011)
Hosseinzadeh, Foroogh and Bouchard, Peter
In : Second International Conference on Advances in Nuclear Materials (ANM-2011) (09-11 Feb 2011, Mumbai, India)


A novel cutting strategy for reducing plasticity induced errors in residual stress measurements made with the contour method (2011)
Traore, Yeli; Bouchard, Peter; Francis, John and Hosseinzadeh, Foroogh
In : ASME Pressure Vessels and Piping Conference 2011 (17-21 Jul 2011, Baltimore, USA)


Residual stress measurements in an edge welded beam specimen (2010)
Hosseinzadeh, Foroogh; Toparli, Muhammed and Bouchard, Peter
In : ASME 2010 Pressure Vessels and Piping Conference (18-22 Jul 2010, Bellevue, Seattle Washington)


Prediction and measurement of through thickness residual stresses in large quenched components (2009)
Hosseinzadeh, F.; Mahmoudi, A. H.; Truman, C. E. and Smith, D. J.
In : World Congress on Engineering (WCE 2009) (1-3 Jul 2009, London, U.K.)


Residual stresses in a machined and shrink fitted assemblies (2008)
Su, Bin; Hosseinzadeh, Foroogh; Smith, David and Truman, Chris
In : 8th International Conference on Residual Stresses (ICRS8) (6-8 Aug 2008, Denver, CO, USA)


Measurement of residual stresses in large engineering components (2007)
Hosseinzadeh, F.; Truman, C. and Smith, D.
In : Experimental Analysis of Nano and Engineering Materials and Structures, Proceedings of the 13 th International Conference on Experimental Mechanics (01-06 Jul 2007, Alexandroupolis , Greece)


Measured residual stresses in large steel rolling components (2007)
Smith, D.; Hosseinzadh, F. and Truman, C.
In : Iron & Steel Technology Conference and Exhibition (07-10 May 2007, Indianapolis, Indiana, USA)


Measurement and mapping of through thickness residual stresses in large steel rolling components (2007)
Hosseinzadeh, Foroogh; Truman, Chris and Smith, David
In : 3rd International Steel Conference on New Developments in Metallurgical Process Technologies (METECH) (11-15 Jun 2007, Duesseldorf, Germany)