Numerical Simulation of Residual Stresses Induced by MIG Welding Considering Initial Conditions

Abstract:

This research describes the numerical simulation of welding residual stresses (WRS)induced by Metal Inert Gas (MIG) welding, explicitly emphasizing the role of initial conditions. MIGwelding is a widely and commonly adopted process in different industries due to its strength andefficiency; however, it generates welding residual stresses that can influence welded components'structural integrity and performance. The numerical simulation calculates various initial conditions,such as pre-existing stresses, temperature variations, material characteristics, and so on, to model thewelding process accurately and with accurate results. By using finite element analysis or numericalsimulation, this study predicts and estimates the intensity and distribution of welding residual stressesin welded joints for optimizing welding parameters to reduce adverse effects on welded structures. Acomparison between non-destructive testing, such as X-ray diffraction (XRD) measurements andnumerical simulations, shows good agreement in assessing residual stresses and validating theaccuracy of the numerical model. Based on the numerical simulation software, the numericalcalculation and analysis of residual stress field under different preheating temperatures for pipewelding were carried out in this paper. The effects of different preheating temperatures on post-weldresidual stress were mainly studied. This approach enables comprehensive calculation of stressdistributions, including axial and hoop stresses across different weld pipes on the surface orientations,offering insights into critical stress areas and potential failure points. These findings demonstrate theutility of numerical simulations as an effective tool for enhancing welded structure design.

• Periodical: Materials Science Forum (Volume 1153)
• Pages: 33-41
• DOI: https://doi.org/10.4028/p-bHfk2w
• Online since: June 2025
• Authors: Mahmood Alhafadhi*, Mohammed Ahmed Shehab, Masar Alsigar, S. Santhosh Kumar, Saleh Suliman Saleh Elfallah, Alden Abd Alal Sahm, Mobark Haider Faisal Helal
• Keywords: Numerical Simulation, Residual Stresses, Welding Parameters

References

[1] Goldak, John, Aditya Chakravarti, and Malcolm Bibby, "A new finite element model for welding heat sources," Metallurgical transactions, vol. 15, pp.299-305,1984.

DOI: 10.1007/bf02667333

[2] Elfallah, s. S. S., "Study the influence of welding parameters by taguchi's design on the mechanical properties of welded mild steel (S235jr)", Jurnal teknologi, vol. 85, no.4, pp.55-66, 2023.

DOI: 10.11113/jurnalteknologi.v85.19653

[3] Alhafadhi, M., Alsigar, M., Vemanaboina, H., Mohanad, F. "Modeling and Measuring Residual Stresses in a Thick-Walled Pipe Structure Welded with a Buried-Arc Technique: A Comparative Study," Scientific Books of Abstracts, no.2, pp.7-7, 2023.

[4] Hasan Al-Hafadhi, M., Krallics, G.,"Prediction and numerical simulation of residual stress in multi-pass pipe welds. Pollack Periodica, vol. 16 no.2, pp.7-12, 2021.

DOI: 10.1556/606.2020.00127

[5] Alhafadhi, M. H., Krallics, G., "Simulation of the residual stress in a multi-pass oil and gas pipe weld joint," In Journal of Physics: Conference Series IOP Publishing, vol. 1527, no. 1, p.012005, 2020.

DOI: 10.1088/1742-6596/1527/1/012005

[6] Alhafadhi, M. H., Krallics, G., "Numerically simulated prediction of residual stresses in welding considering phase transformation effects," In Journal of Physics: Conference Series, vol. 1527, no. 1, pp.012-017, 2020.

DOI: 10.1088/1742-6596/1527/1/012017

[7] Alhafadhi, M., Krallics, G., "Finite element modelling of residual stresses in welded pipe welds with dissimilar materials," Hungarian materials and chemical sciences and engineering, vol. 45, no.4, pp.7-19, 2020.

[8] Alhafadhi, M. H., Krállics, G., "Effect of the welding parameters on residual stresses in pipe weld using numerical simulation," Design of machines and structures: a publication of the university of miskolc, vol. 10, no.1, pp.5-12., 2020.

DOI: 10.32972/dms.2020.001

[9] Alsigar, M., Alhafadhi, M., Pereverzev, P., Mohanad, F., "Optimizing Grinding Cycle Times for Maximum Efficiency through Dynamic Programming," Scientific Books of Abstracts, no.2, pp.12-12, 2023.

[10] Alsigar, M., Alhafadhi, M., Pereverzev, P., "Developing Optimal Automated Cycles for Achieving Maximum Efficiency Using Dynamic Programming," In International Conference on Industrial Engineering Cham: Springer Nature Switzerland, pp.542-554, 2024.

DOI: 10.1007/978-3-031-65870-9_50

[11] Alhafadhi, M. H., Krallics, G., "The effect of heat input parameters on residual stress distribution by numerical simulation," In IOP Conference Series: Materials Science and Engineering, vol. 613, no. 1, p.012035, 2019.

DOI: 10.1088/1757-899x/613/1/012035

[12] Alhafadhi, M. H., Krallics, G., "Numerical simulation prediction and validation two-dimensional model weld pipe," Machines. Technologies. Materials, vol. 13, no.10, pp.447-450, 2019.

[13] Lukács, J., Mobark, H. F. H., & Dobosy, Á., "High cycle fatigue resistance of 700 MPa and 960 MPa strength categories high strength steels and their gas metal arc welded joints," In Vehicle and Automotive Engineering 3: Proceedings of the 3rd VAE2020, Miskolc, Hungary, vol.3, pp.539-555, 2021.

DOI: 10.1007/978-981-15-9529-5_47

[14] Mobark, H. F. H., Dobosy, Á., Lukács, J., "Mismatch effect influence on the HCF resistance of high strength steels and their GMA welded joints," In Vehicle and Automotive Engineering 2: Proceedings of the 2nd VAE2018, Miskolc, Hungary, vol.3, pp.755-767, 2018.

DOI: 10.1007/978-3-319-75677-6_64

[15] Mobark, H., & Lukács, J., "Mismatch effect on fatigue crack propagation limit curves of GMAW joints made of S960QL and S960TM," Design of Machines and Structures, vol. 10, no.1, pp.28-38, 2020.

DOI: 10.32972/dms.2020.004

[16] Mobark, H. F. H., Lukács, J., "Efficient application of S690QL type high strength steel for cyclic loaded welded structures," In Solutions for Sustainable Development, pp.325-336, 2019.

DOI: 10.1201/9780367824037-39

[17] Mobark, H., & Lukács, J., "HCF design curves for high strength steel welded joints," Design of Machines and Structures, vol. 8, no.2, pp.39-51., 2018.

[18] Alden Abd Al Al, S., Meilinger, Á., Gáspár, M., "Physical Heat Cycle Measurement of Resistance Spot Welding," Key Engineering Materials, vol. 989, pp.65-75, 2024.

DOI: 10.4028/p-tb0owj

[19] Abd Al Al, S. A., Meilinger, Á., Gáspár, M., Lukács, J., "High Cycle Fatigue Testing of Lap Shear RSW Joints from Martensitic MS1400 Steel Sheets," In Materials Science Forum,vol. 1095, pp.139-151,2023.

DOI: 10.4028/p-o9mwsq

[20] Abd al al, S. A., Meilinger, Á., "Investigation of Resistance Spot Welded Joints Made on Ultra-high-Strength Steel Sheets," In Vehicle and Automotive Engineering, vol.1, no.1 pp.981-994, 2022.

DOI: 10.1007/978-3-031-15211-5_82

[21] Meilinger, Á., Prém, L., Abd Al Al, S. A., Gáspár, M., "Comparison of RSW technologies on DP steels with modified instrumented Charpy impact test," Welding in the World, vol.67, no.8, pp.1911-1922, 2023.

DOI: 10.1007/s40194-023-01526-2

[22] Alhafadhi, M., Alsigar, M., Zahraa A, O., Bézi, Z., Sahm, A. A. A., Reddy, P. R., "Influence of heat input and preheating on residual stresses in pipe weld," Pollack Periodica ,vol.19, no.2, pp.42-47, 2024.

DOI: 10.1556/606.2023.00589