Finite element analysis of the effect of welding heat input and layer number on residual stress in repair welds for a stainless steel clad plate

Stainless steel clad plate is widely used in petroleum, chemical and medicine industries due to its good corrosion resistance and high strength. But cracks are often formed in clad layer during the manufacture or service, which are often repaired by repair welding. In order to ensure the structure integrity, the effects of residual stress need to be considered. The objective of this paper is to estimate the residual stress and deformation in the repair weld of a stainless steel clad plate by finite element method. The effects of heat input and welding layer number on residual stresses and deformation have been studied. The results show that large residual stresses have been generated in the repair weld. The heat input and layer number have great effects on residual stress distribution. With the heat input and welding layer number increasing, the residual stresses are decreased. Using multiple-layer welding and higher heat input can be useful to decrease the residual stress, which provides a reference for optimizing the repair welding technology of this stainless steel clad plate.     

Simplified FE welding simulation of fillet welds – 3D effects on the formation residual stresses

In this study two- and three-dimensional finite element welding simulations have been carried out. The welded component studied is a T-type fillet weld which is frequently used in the heavy vehicle machine industry with plate thicknesses of eight and 20 mm, respectively. The software’s used for the welding simulations is MSC.Marc and ANSYS. The objective is to study the formation of the residual stresses due to 3D effect of the welding process. Moreover, welding simulations using solid models and contact models in the un-fused weld roots were carried out in order to investigate the possible effect with respect to the residual stresses. Residual stress measurements were carried out using X-ray diffraction technique on the manufactured T-welded structure. The 2D residual stress predictions shows good agreement with measurements, hence the 2D welding simulation procedure is suitable for residual stress predictions for incorporation in further fatigue crack growth analysis from weld defects emanating from the weld toe and the un-fused root.     

焊缝匹配影响焊接残余应力的研究

采用有限元法对相同温度场的焊缝与母材强度和线膨胀系数匹配影响焊接残余和的规律进行了数值模拟,计算结果表明：等强度等匹配的焊缝区纵向残余应力水平高达母材的屈服强度,     

Failure Analysis of AISI-304 Stainless Steel Styrene Storage Tank

This paper presents the failure analysis of AISI-304 stainless steel tank that was fabricated by welding and used for the storage of styrene monomers. After about 13 years of satisfactory operation, significant cracking was observed adjacent to the weld joints and in base plate near tank foundation. Weld repair was by shielded gas arc welding using AISI 308 stainless steel filler wire. The failed base plate was replaced with the new AISI 304 base plate of same thickness. After a short period of time, seepage was observed along the weld bead. Upon nondestructive testing cracks were found in the heat-affected zone and in the base plate. The failure investigation was carried out on welded and base plate samples using spectroscopy, optical and scanning electron microscopy, fractography, SEM–EDS analysis, microhardness measurements, tensile and impact testing. The results revealed transgranular cracks in the HAZ and base plate, and the failure was attributed due to stress corrosion cracking. Cracks initiated as a result of combined action of stresses developed during welding and the presence of a chloride containing environment due to seawater. It was further observed that improper welding parameters were employed for weld repair which resulted in sensitization of the structure and postweld heat treatment to remove weld sensitization and minimize the residual stresses was not done.     

Residual stress reduction in the penetration nozzle weld joint by overlay welding

Stress corrosion cracking (SCC) in the penetration nozzle weld joint endangers the structural reliability of pressure vessels in nuclear and chemical industries. How to decrease the residual stress is very critical to ensure the structure integrity. In this paper, a new method, which uses overlay welding on the inner surface of nozzle, is proposed to decrease the residual stresses in the penetration joint. Finite element simulation is used to study the change of weld residual stresses before and after overlay welding. It reveals that this method can mainly decrease the residual stress in the weld root. Before overlay welding, large tensile residual stresses are generated in the weld root. After overlay weld, the tensile hoop stress in weld root has been decreased about 45%, and the radial stress has been decreased to compressive stress, which is helpful to decrease the susceptibility to SCC. With the increase of overlay welding length, the residual stress in weld root has been greatly decreased, and thus the long overlay welding is proposed in the actual welding. It also finds that this method is more suitable for thin nozzle rather than thick nozzle.     

FEM prediction of welding residual stresses in a SUS304 girth-welded pipe with emphasis on stress distribution near weld start/end location

A finite element approach based on Quick Welder software is developed to simulate welding temperature field and welding residual stress distribution in a 3D multi-pass girth-welded pipe model. The characteristics of welding residual stress distributions in a SUS304 stainless steel pipe induced by heating with a tungsten inert gas arc welding torch are investigated numerically. Meanwhile, an emphasis is focused on examining the welding residual stress distributions in and near the weld start/end location. Moreover, the residual stresses predicted by the present computational approach are compared with the measured data; and the comparison suggests that the numerical simulation method has basically captured the feature of welding residual stress distribution near the weld start/end region. The numerical simulation results show that both the hoop and the axial residual stresses near the weld start/end region have sharp gradients and are significantly different from those in the steady range.     

Numerical and experiment analysis of residual stress on magnesium alloy and steel butt joint by hybrid laser-TIG welding

Hybrid welding technology has received significant attention in the welding of dissimilar materials recently. While, great welding residual stress and deformation often result by the difference of coefficient of thermal expansion This study describes the thermal elastic–plastic analysis using finite element techniques to analyze the thermo mechanical behavior and evaluate the residual stresses and welding distortion on the AZ31B magnesium alloy and 304L steel butt joint in laser-TIG hybrid welding. A new coupled heat source model was developed which combined by double-elliptic planar distribution, double-ellipsoid body distribution and Rotary–Gauss body distribution model. From the results, it can be concluded that the temperature distribution at the hybrid weld region is exposed to faster rate of heating and cooling in hybrid welding than TIG. Furthermore, compared to the welding stress distribution on the TIG weld, residual stress σ_y is found about 20% higher on hybrid weld joints, and the residual stress on the 304L steel plate is lower than that on the AZ31B magnesium plate.     

Surface residual stress evaluation in double-electrode butt welded steel plates

Surface residual stress evaluation for double-electrode welding was studied. The stresses were monitored after each operational step: positioning, implementing of constraints, welding and constraints removal. The measurements were performed at the deposited metal, heat affected zone, base metal close to the weld joint and along the plate using the X-ray diffraction method. It was observed differences in the stress evaluations for double-electrode welding which resulted in lower bending distortions and higher values of surface residual stresses, compared with single-electrode welding. This behavior is associated with the stress distribution just after the welding processes in both heat affected zone and base metal close to the fillet for double-electrode welding. The main results from the laboratorial tests indicated lower values of the bending distortions for double-electrode welding compared with the single-electrode. In relation to the residual stress, the double-electrode welding generated, in general, higher stress values in both longitudinal and transversal directions.     

Effects of welding residual stresses on fatigue crack growth behaviour in butt welds of a pipeline steel

In the present test the fatigue crack growth rate in the parent plate, weld and cross-bond regions was measured and the results were correlated with the stress intensity range ΔK and the effective stress intensity range ΔK_eff. It is indicated that the welding residual stresses strongly affect the crack growth rate. For the weld metal and cross-bond compact tension specimens in which crack growth is along the weld line the fatigue crack growth rate increases as the crack grows. However, for the T compact tension specimen in which crack growth is perpendicular to the weld line at a constant value of applied ΔK the crack growth rate initially decreases as the crack grows. Particularly, at a low constant value of applied ΔK the crack growth rate obviously decreases and the crack fails to grow after short crack growth. When the crack grows to intersect the welded zone, the fatigue crack growth rate gradually increases as the crack grows further. It is clear that the effect of welding residual stresses on the crack growth rate is related to the position of the crack and its orientation with respect to the weld line. Finally, the models of welding residual stress redistribution in the compact tension specimens with the growing crack and its influence on the fatigue crack closure are discussed. It appears that for a butt-welded joint one of the crack closure mechanisms may be considered by the bend or rotation deformation of crack faces due to the welding residual stress redistribution as the fatigue crack grows in the welded joint.     

振动时效消除拼焊不锈钢板的残余应力

为了消除超大不锈钢焊接底板的残余应力,研究了采用振动时效(VSR)的方法消除焊接残余应力。应用JB /T5926-91标准对振动时效工艺进行了定性的评价。通过对焊后和振动时效后底板焊缝上残余应力的对比测量,全面地、定量地了解振动时效工艺对残余应力的变化及最终的应力状况的影响,了解了VSR工艺的可行性和有效性,从而实现替代热时效工艺目标。     

高强度钢加劲板焊接残余应力测试及分析

为研究高强度钢的板肋加劲板焊接残余应力分布特点,该文利用切割法对板肋加劲板试件进行了应力测试研究,建立了三维实体热弹塑性有限元模型,采用单元生死和动态约束技术模拟焊缝填充和焊接热输入过程,对比分析了高强度钢和普通钢的应力分布特点,比较研究了母板厚度、肋板厚度、肋板间距和高度对焊接残余应力的影响。研究结果表明:板肋加劲板T型接头角焊缝的焊接顺序与残余应力的分布不相关;高强度钢非焊接区域残余压应力小于普通钢;板件厚度和肋板高度是影响高强度钢的板肋加劲板焊接残余应力的主要因素。     

Behaviour of stresses in circumferential butt welds of steel pipe under superimposed axial tension loading

A computational procedure is presented for analyzing behaviour of stresses in circumferential butt welds of carbon steel pipe subject to superimposed mechanical loading. Three-dimensional uncoupled thermo-mechanical finite element (FE) analysis method is developed in order to predict the weld residual stress states in circumferentially butt-welded steel pipe. The FE method is verified through the experimental work. Then, three-dimensional elastic–plastic FE analysis is carried out to investigate the behaviour of stresses in steel pipe circumferential welds undergoing superimposed axial tension loading using the weld residual stresses and plastic strains obtained from the thermo-mechanical FE method. The simulated results show that spatial variations of the weld residual stresses are present along the circumference and a rapid change of the residual stresses exists at the weld start/stop position, therefore three-dimensional FE analysis is essential to accurately simulate the circumferential welding of steel pipe. Moreover, when axial tension loading is applied to the circumferentially welded steel pipe, bending moment is generated at the weld area caused by the circumferential shrinkage of the weld during welding, thus affecting the axial and hoop stress evolutions in the course of mechanical loading.     

基于Simufact的割草盘控制杆焊接成形质量控制研究

目的保证割草机割草盘控制杆焊后的装配精度和尺寸稳定性。方法采用Simufact Welding软件对割草盘控制杆焊接过程进行模拟仿真。通过建立合适的热源模型,得到焊后变形和焊接应力分布情况。结果椭圆板焊缝处为焊接变形最大的区域,最大总变形量为0.73 mm;焊后最大等效应力为395.59 MPa,且沿焊缝两侧向外扩展,等效应力呈递减趋势。结论通过工装优化方案,实现了焊后残余变形控制,最大变形量由0.73 mm降低到0.41 mm,且未引起焊接残余应力的上升,但焊后残余应力仍处于较高的水平,可通过焊后退火消除残余应力。     

Finite element simulation of the residual stresses in high strength carbon steel butt weld incorporating solid-state phase transformation

This paper presents a sequentially coupled three-dimensional (3-D) thermal, metallurgical and mechanical finite element (FE) model to simulate welding residual stresses in high strength carbon steel butt weld considering solid-state phase transformation effects. The effects of phase transformation during welding on residual stress evolution are modeled by allowing for volumetric changes and the associated changes in yield stress due to austenitic and martensitic transformations. In the FE model, phase transformation plasticity is also taken into account. Moreover, preheat and inter-pass temperature are included in the modeling process. Based on the FE model, the effects of solid-state phase transformation on welding residual stresses are investigated. The results indicate the importance of incorporating solid-state phase transformation in the simulation of welding residual stresses in high strength carbon steel butt weld.     

Finite Element Analysis of Modeling Residual Stress Distribution in All-position Duplex Stainless Steel Welded Pipe

On the basis of the thermal-elastic-plastic theory, a three-dimensional finite element numerical simulation is performed on the girth welded residual stresses of the duplex stainless steel pipe with ANSYS nonlinear finite element program for the first time. Three-dimensional FEM using mobile heat source for analysis transient temperature field and welding stress field in circumferential joint of pipes is founded. Distributions of axial and hoop residual stresses of the joint are investigated. The axial and the hoop residual stresses at the weld and weld vicinity on inner surface of pipes are tensile, and they are gradually transferred into compressive with the increase of the departure from the weld. The axial residual stresses at the weld and weld vicinity on outer surface of pipes is compressive while the hoop one is tensile. The distributions of residual stresses compared positive-circle with negative-circle show distinct symmetry. These results provide theoretical knowledge for the optimization of p     

Numerical modelling and experimental investigation on welding residual stresses in large‐scale tubular K‐joints

This paper is devoted to the experimental and numerical assessment of residual stresses created by welding in the region surrounding the weld toe of tubular K‐shaped joints (i.e. region most sensitive to fatigue cracking). Neutron‐diffraction measurements were carried out on K‐joints cut from large‐scale truss beams previously subjected to high cycle fatigue. Tri‐axial residual stresses in the transverse, longitudinal and radial direction were obtained from the weld toe as a function of the depth in the thickness of the tube wall. In addition, thermomechanical analyses were performed in three‐dimensional using ABAQUS and MORFEO finite element codes. Experimental and numerical results show that, at and near the weld‐toe surface, the highest residual stresses are critically oriented perpendicularly to the weld direction, and combined with the highest externally applied stresses. Based on a systematic study on geometric parameters, analytical residual stress distribution equations with depth are proposed.     

Residual stress field determination in welds by means of X‐ray,synchrotron and neutron diffraction

To what extent the welding residual stresses influence fatigue is still unclear and matter of debate. An important reason for this lack of clarity is that the exact determination of residual stress fields in welds is complicated which leads to conservative assumptions about these stresses in the fatigue design codes. The advances in the diffraction analysis of materials offer the opportunity for the full‐field residual strain mapping in welds albeit at the cost of time and technical complexity. In this work residual stress field determination in welded S1100QL specimens by means of the x‐ray, synchrotron and neutron diffraction techniques was undertaken. The results revealed that the maximum values of surface residual stresses are not as frequently assumed, as high as the yield strength in small scale specimens. At the weld toe which could serve as a fatigue crack initiation site, even lower residual stresses than the weld centreline could be present. The in‐depth measurements revealed that the effective part of the residual stress field which could be decisive for the fatigue failure initiation is concentrated at the surface of the weld.     

反应堆压力容器接管安全端焊接残余应力模拟及其焊接参数优化研究

目的 针对反应堆压力容器接管安全端焊接残余应力较大易导致应力腐蚀开裂的问题,探究焊接工艺参数对焊接残余应力的影响,并寻找最佳工艺参数。方法 利用有限元参数化建模方法建立反应堆压力容器接管安全端的三维热-力耦合模型,模拟其焊接过程,研究焊接残余应力的变化情况。采用正交试验设计法分析了焊接电流、焊接速度及层间冷却时间对焊后最大等效应力的影响,建立了焊后最大等效应力与焊接电流、焊接速度及层间冷却时间的二次回归模型,基于该模型利用遗传算法寻优焊接参数。结果 焊接残余应力峰值靠近熔合区位置,残余应力较高,超过了材料的屈服应力;各参数按对焊后等效残余应力峰值的影响由大到小的顺序依次为焊接速度、焊接电流、层间冷却时间。正交试验所得最佳工艺参数如下：焊接电流为610 A,焊接速度为20 mm/s,层间冷却时间为400 s,经遗传算法进一步优化后所得的最佳参数如下：焊接电流为610 A,焊接速度为23 mm/s,层间冷却时间为427 s。通过仿真验证遗传算法优化结果,得到焊接残余应力的峰值为373 MPa,比未优化前减小了44 MPa。结论 优化后的工艺参数有效降低了焊接残余应力,提高了反应堆压力容器接...     

Cruciform fillet welded joint fatigue strength improvements by weld metal phase transformations

Arc welding typically generates residual tensile stresses in welded joints, leading to deteriorated fatigue performance of these joints. Volume expansion of the weld metal at high temperatures followed by contraction during cooling induces a local tensile residual stress state. A new type of welding wire capable of inducing a local compressive residual stress state by means of controlled martensitic transformation at relatively low temperatures has been studied, and the effects of the transformation temperature and residual stresses on fatigue strength are discussed. In this study, several LTTW (Low Transformation‐Temperature Welding) wires have been developed and investigated to better characterize the effect of phase transformation on residual stress management in welded joints. Non‐load‐carrying cruciform fillet welded joints were prepared for measurement of residual stresses and fatigue testing. The measurement of the residual stresses of the three designed wires reveals a compressive residual stress near the weld toe. The fatigue properties of the new wires are enhanced compared to a commercially available wire.     

Using FEM to determine the thermo-mechanical stress in tube to tube–sheet joint for the SCC failure analysis

The stress corrosion cracking in a weld of the tube to tube–sheet region of heat exchangers is a common problem. Thermo-mechanical stress in tube to tube–sheet joints including welding effect should be determined in this situation for failure analysis. In this paper, the Finite Element Method (FEM) is used to predict the thermo-mechanical stresses including welding residual stress in a tube to tube–sheet weld. Both the thermo-mechanical stress distribution with and without the welding residual stress have also been investigated by numerical simulation. The welding, operating temperature, and operating pressure have effect on total stresses. Especially, the welding residual stresses play an important role in total stress state in tube to tube–sheet joints. Geometric discontinuities of the vicinity of gap cause the welding joint to experience a local stress concentration. A high tensile stress in the tube to tube–sheet region has been demonstrated by FEM, which is the stress aspect for the SCC phenomenon of austenitic stainless steel in chloride environment.