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Numerical Modeling of Controlled Multi-Step Expansion in Plasma Arc Welded AISI 316 Stainless-Steel Tubes

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Abstract:

The increasing demand for reliable and high-performance heat-transfer components has stimulated the development of robust joining and forming strategies for thin-walled stainless-steel tubes. In this work, the Controlled Tube Expansion of Plasma Arc Welded AISI 316 stainless-steel tubes was investigated through a combined experimental and numerical approach. Welded tubes with an initial diameter of 130 mm were expanded to 180 mm using a three-step mechanical expansion process, and six different expansion sequences were experimentally evaluated. Finite element simulations were performed using a coupled thermo-mechanical model incorporating a damage-based fracture criterion to predict material failure during expansion. Numerical predictions were in good agreement with experimental observations and allowed the identification of a critical cumulative damage threshold governing tube failure. Based on these results, a processability domain was defined, clearly distinguishing safe and unsafe expansion paths. The study demonstrates that tube expandability is strongly dependent on the deformation path and highlights the importance of progressive expansion strategies for maximizing material ductility while preventing fracture.

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Periodical:

Solid State Phenomena (Volume 389)

Pages:

115-123

DOI:

https://doi.org/10.4028/p-0SlKmg

Citation:

Cite this paper

Online since:

April 2026

Authors:

Francesco Borda*, Serafino Caruso, Luigino Filice

Keywords:

AISI 316 Stainless Steel, Controlled Tube Expansion, Digital Twin, Finite Element Modelling, Multi-Step Expansion, Plasma Arc Welding (PAW)

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Creative Commons CC BY 4.0

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* - Corresponding Author

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