Papers by Keyword: Welding Residual Stress (WRS)

Abstract: Welding residual stress is of major concern for structural integrity assessment in industrial components. Shear and volume strains resulting from the austenite-martensite-transformation affect the development of residual stress during welding. Controlling the phase transformation allows adjustment of the welding residual stress. Low transformation temperature (LTT) weld filler materials exhibiting reduced MS-temperatures allow postponing the phase transformation. The associated strain arising from the delayed transformation compensates for the thermal contraction strains and as such may reduce tensile or even introduce compressive residual stress. In this article we discuss the tri-axial residual stress distribution in 15 mm S690Q steel plates joined with LTT filler materials with 10 wt% Cr and a Ni-content that varies from 8 to 12 wt%. Using complementary synchrotron X-ray and neutron diffraction stress analysis the macroscopic residual stress was derived from the phase specific lattice strain and phase fraction of martensite and retained austenite, respectively. The local phase specific unstrained lattice parameters were determined using stress relieved combs. The investigation revealed increasing phase fraction of retained austenite with increasing Ni-content. Further, independent of the Ni-content in each weld in the fusion zone, significant compressive residual stresses were found in the longitudinal direction, which are balanced by tensile residual stresses in the heat affected zone (HAZ). In the weld transverse and normal direction the stress distribution is qualitatively similar but less in magnitude. The increased amount of retained austenite reduces the compressive stress arising from shear and volume strains during the delayed phase transformation and therefore no significant increase in compression was observed for decreasing M_S-temperatures.

Abstract: An Abaqus Extension, in the form of an Abaqus/CAE Plug-In, is presented that enables an easy, efficient, model-tree based approach to setup all aspects of a welding model from within Abaqus/CAE. Specifically, the paper describes the extension to 3-D of a similar capability, namely the 2-D Abaqus Welding Interface (AWI), that currently exists for automating most of the repetitive, time-consuming tasks associated with building a welding model in a traditional CAE environment to facilitate weld simulations. The tasks supported by the 3-D AWI include weld-bead definitions based on simple cross-sectional geometric entity picks, options for geometry- or element-based bead-chunking in the weld direction, automatic definition of weld passes, steps and boundary conditions for each pass, and set-up of both the thermal and stress analysis models. The 3-D AWI is expected to make the normally time-consuming welding analysis setup significantly faster. The use of the AWI is demonstrated on a six-pass plate welding problem described in the literature.

Abstract: Welding residual stress and subsequent distortions are a common problem during fabrication. Several techniques for controlling residual stress and distortion during welding, amongst which transient thermal tensioning is one of the more promising methods. Thermal tensioning can be achieved by two side heaters moving along with the weld heat source. The concept of transient thermal tensioning induces a redistribution of the stress field in the welded plate by altering the thermal field. In this paper, the results are presented on the mitigation of out-of-plane deformation during gas tungsten arc butt welding of 2 mm thick AISI-316L stainless steel. Acetylene-air burners are applied as side heaters. The thermal tensioning process induces a number of additional process parameters including the intensity, the size and the location of the heaters. A thermo-mechanical (TM) finite element model is used to cope with the complexity of the process. The model provides a better understanding of the development of the stress field, both in conventional and transient thermal tensioned welds and of the mechanisms which mitigate distortion. The model is validated by temperature, stress and distortion measurements. It appears that the redistribution of stresses and the introduction of tensile stresses by side heating is the main mechanism responsible for the reduction of distortion.

Abstract: To reduce welding residual stress (WRS) of a class 3 pressure vessel during the reconstruction, temper bead welding technique (TBWT) was applied to the container. To compare WRS causing by common welding and TBWT, WRS of the two different kinds of welded specimens of 16Mn steel were measured and evaluated by X-ray method. To study the effect of butt weld reinforcement height on WRS, welds with and without weld reinforcement were measured. The results show that longitudinal stress was reduced obviously and the lateral stress is the maximum principal stress for TBWT; WRS of TBWT T-shape specimens were obviously decreased which proves TBWT is better than common welding procedure; WRS was decreased by more than 25% after removing the weld reinforcement and further proves that it is one of effective ways to reduce WRS in engineering application.

Abstract: The fatigue tests of Q235B steel unload longitudinal fillet welded joints containing high welding residual stress were carried out. And the effect of welding residual stress on fatigue performance of the welded joints treated by ultrasonic peening has been studied. Specimens were divided into four groups: as welded, specimens treated by ultrasonic peening(UP), specimens treated by stress relief treatment(SRT) and specimens treated by both ultrasonic peening and stress relief treatment(UP+SRT). Test results show that the effect on fatigue performance of the welded joints treated by ultrasonic peening from welding residual stress is small. It is safe that using the small specimens treated by ultrasonic peening and not containing high welding residual stress to appraise the fatigue performance improvement on large-scale welded structures which are as the same junction style and thickness as the small.

Abstract: In order to solve the problem of crack appeared in Francis turbine runner, the welding residual stress of Francis turbine runner is regulated and controlled by means of numerical simulation from the view of subsection welding, local heating and local peening. The results show that the length of welding section of blade outlet and the welding direction in the subsection welding process influence the residual stress of the turbine blade. For the local heating technology, the decreasing effect on residual stress increases with the increase of heating time, heating temperature and heating area. The welding residual stress of dangerous region decreases and then increases with the increase of heating distance. Moreover, the peening effect is very clear when the temperature of material in the peening region reaches its own plastic temperature.

Abstract: The ultra narrow gap welding process is suitable to the thick plate, ultra-thick plate welding with the characteristic of highly effective, high quality, low cost, low energy consumption and so on, and is easy to realize the mechanization and the automation. In this paper, the numerical simulation and technical experiment are used to study the form, grow and distribution regulation of the welding temperature field, stress field in welding joint with UNG MAW. Using the calculation to the thickness of 32mm, an example to simulate the magnitude and distribution of the residual stress in welding joint is given. Research shows that it is an effective analysis method to heat process and mechanic behavior in the welding by using finite element method numerical simulation and few experiments. Keywords: UNG MAW, Welding residual stress, Finite element method, Numerical simulation

Abstract: Aiming at adscititious magnetic field effect GTAW arc, decrease the maximum welding residual which by arc shape be changed, avoid the temperature excessive focus on welding pool, reduce temperature gradient and so on. Arc heat source model of GTAW under the magnetic field was established, also consider physical properties of materials varying with the temperature and the influence transformation, through the method of killing or activating elements treatment such as melting or solidification by welding pool, 3D FEM simulation analysis for the temperature gradient and residual stress size distribution to GTAW welded joints compared to on magnetic field or not. The results show that maximum weld longitudinal residual stress and transverse residual stress were respectively reduced by 12.3% and 13.6% when compared to no magnetic field, also have blind hole measuring method measure welding residual stress, Test measurement and simulation values were basically consistent.

Abstract: In this paper, the non-scallop welding joint as the research object is analyzed by ABAQUS software where the implicit analysis method is used to define the residual stress distributions. Based on the thermal analysis, the non-linear quasi-static analysis is also taken, and then the results are compared with the experimental results. The results demonstrated higher accuracy of the finished simulation.

Abstract: To simulate preheating and postweld heat treatment of Q345 steel pipe welding, the finite element model was established. The welding process was simulated by method of the ANSYS element birth and death technique. In this paper, to obtain the distribution of the temperature field and stress field in different situations, preheating processes with two different values of temperature and postweld heat treatment process were simulated respectively. The results show that preheating can homogenize residual stress distribution of the weldment and decrease the residual stress. The heat treatment reduces the residual stress in inner and outer walls by 24% and 70% respectively and the stress distribution is more even and stress concentration is reduced.