Minimisation of the residual stress in the heat affected zone by means of numerical methods

2007 ◽  
Vol 28 (8) ◽  
pp. 2295-2302 ◽  
Author(s):  
A.G. Olabi ◽  
G. Casalino ◽  
K.Y. Benyounis ◽  
A. Rotondo
Keyword(s):  
Residual Stress ◽  
Numerical Methods ◽  
Heat Affected Zone

Numerical Methods to Predict Distortion in Welded Components

2008 ◽  
Author(s):  
N. A. Leggatt ◽  
R. J. Dennis ◽  
P. J. Bouchard ◽  
M. C. Smith
Keyword(s):  
Residual Stress ◽  
Numerical Methods ◽  
Structural Integrity ◽  
Large Strain ◽  
Stress Fields ◽  
Specimen Thickness ◽  
Single Bead ◽  
Stress Profiles ◽  
Welding Processes ◽  
Integrity Assessments

Numerical methods have been established to simulate welding processes. Of particular interest is the ability to predict residual stress fields. These fields are often used in support of structural integrity assessments where they have the potential, when accurately characterised, to offer significantly less conservative predictions of residual profiles compared to those found in assessment codes such as API 579, BS7910 and R6. However, accurate predictions of residual stress profiles that compare favourably with measurements do not necessarily suggest an accurate prediction of component distortions. This paper presents a series of results that compare predicted distortions for a variety of specimen mock-ups with measurements. A range of specimen thicknesses will be studied including, a 4mm thick DH-36 ferritic plate containing a single bead, a 4mm thick DH-36 ferritic plate containing fillet welds, a 25mm thick 316L austenitic plate containing a groove weld and a 35mm thick esshete 1250 austenitic disc containing a concentric ring weld. For each component, distortion measurements have been compared with the predicted distortions with a number of key features being investigated. These include the influence of ‘small’ vs ‘large’ strain deformation theory, the ability to predict distortions using simplified analysis methods such as simultaneous bead deposition and the influence of specimen thickness on the requirement for particular analysis features. The work provides an extremely useful insight into how existing numerical methods used to predict residual stress fields can be utilised to predict the distortions that occur as a result of the welding fabrication process.

scholarly journals Experimental Research and Numerical Simulation of Weld Repair with High Energy Spark Deposition Method

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 980 ◽  
Author(s):  
Yingjie Zhang ◽  
Kai Yang ◽  
Jianping Zhao
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Residual Stress ◽  
Heat Affected Zone ◽  
Welded Joints ◽  
High Energy ◽  
Repair Welding ◽  
Repair Processes ◽  
Repair Technology ◽  
Surface Repair

For long-serviced pressure equipment that is under severe working conditions such as a high temperature, high pressure, and corrosion, the material properties and structure will be unavoidably damaged or degraded, especially cracks and other damages at key positions such as welded joints, which seriously threaten the safe operation of the equipment. In order to promote the sustainable development of industries such as the chemical and petrochemical industries, remanufacturing technology has emerged worldwide, and various surface repair processes have also rapidly developed. As an important branch of surface repair technology, the high energy spark deposition (HESD) process is a new pulse cold welding repair technology developed from electro-spark deposition, which combines the advantages of multiple surface repair processes. The HESD process has the characteristics of a smaller heat affected zone and lower welding residual stress. It is a new type of repair method that is worthy of popularization and application. The process has been initially applied in the fields of surface modification and die steel repair. In this paper, the application of the HESD process to the repair of welded joints was introduced, the mechanical properties of the joints and the residual stress distribution after welding were analyzed, and the feasibility of HESD as a repair welding method for pressure structures was discussed. First, a numerical simulation of the temperature and stress field of HESD was proposed by using ABAQUS and the related subprograms, and the validity of the simulation results was verified by the residual stress test with the indentation strain method. Due to the precise control of the heat and pulse discharge working mode, the heat-affected zone and deformation caused by the HESD were extremely small, and the residual stress that was generated was low and only concentrated on the repair welding seam. Second, according to the numerical simulation and the test results of the mechanical properties of the welded joint, the optimal repair welding process parameters were obtained through the orthogonal experiment: peak current 45 A, pulse width 90 ms, and output voltage 10 V.

Complementarity of experimental and numerical methods for determining residual stress states

2009 ◽  
Vol 24 (S1) ◽  
pp. S3-S10
Author(s):  
George Roy
Keyword(s):  
Residual Stress ◽  
Numerical Methods ◽  
Strain Tensor ◽  
Diffraction Method ◽  
Hole Drilling ◽  
Material Surface ◽  
Engineering Structures ◽  
Hole Drilling Method ◽  
Stress States ◽  
Element Method

Residual stress states in engineering structures are usually determined by measuring components of stress tensors with depth below the material surface. There are destructive and nondestructive methods to measure strain tensor components and convert them into stress tensor components by a variety of techniques derived from constitutive (material) equations. In this study, four methods for determining the strain tensor components are presented: X-ray diffraction method (XRDM), magnetic Barkhausen noise method (MBNM), hole drilling method (HDM), and cut-and-section method (CSM); the first two are nondestructive, and the third and fourth are semidestructive and destructive, respectively. A complementarity of the experimental and two numerical methods such as boundary element method and finite element method is explained. An application of the experimental and numerical methods to measure residual stress states in an industrial component, an L-shaped part of a supporting column in a high voltage structure, is presented.

scholarly journals Process Induced Residual Stress Effect on Fatigue Lifetime of Automotive Steel Components

2014 ◽  
Vol 996 ◽  
pp. 808-813
Author(s):  
Elias Merhy ◽  
Ngadia Taha Niane ◽  
Bastien Weber ◽  
Philippe Bristiel
Keyword(s):  
Residual Stress ◽  
Heat Affected Zone ◽  
High Cycle Fatigue ◽  
Low Cycle Fatigue ◽  
Welding Process ◽  
Fatigue Loading ◽  
Stress Effect ◽  
Cycle Fatigue ◽  
Residual Stress Field ◽  
Fatigue Lifetime

Metal Active Gas (MAG) welding process of steel sheets generates, in the vicinity of the welding joint, the well-known Heat Affected Zone (HAZ) in which the material presents more microstructural defects compared to the original metal. Since high cycle fatigue is largely dependent on the material microstructure features, the HAZ is considered as the weakest zone under high cycle fatigue loading. In addition, the welding causes, in the Heat Affected Zone, irreversible plastic strains that induce important residual stress fields in this critical zone of the structure. Therefore, in order to properly predict the high cycle fatigue life time of the welded automotive components, it is of primordial importance to first identify and then consider, if necessary, the welding induced residual stress field in the structure modeling. In this work, it is found that residual stresses have non-negligible impact on high cycle fatigue lifetime, while its effect is minor in the low cycle fatigue domain.

scholarly journals The Effects of Different Gaps on the Weld Morphology, Microstructure and Residual Stress of AH36 Steel were Studied by Laser Arc Hybrid Welding

2022 ◽  
Vol 2160 (1) ◽  
pp. 012039
Author(s):  
Xiaoqi Hou ◽  
Xin Ye ◽  
Xiaoyan Qian ◽  
Haohao Jing ◽  
Peilei Zhang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Laser Power ◽  
Welding Process ◽  
Lower Surface ◽  
Thick Sheet ◽  
Hybrid Welding ◽  
Upper Bainite ◽  
Better Than

Abstract In this study, laser (TruDisk16002)-arc (MAG) hybrid welding was used to weld a 5mm thick sheet of AH36 steel with a gap of 0mm and 1mm. The results show that when the current of MAG is 205A, the voltage is 31.9V, and the laser power is 7.5KW, the welds of 0mm gap and 1mm gap are well formed, showing a typical nail shape, and the 0mm gap weld is better than 1mm. Under the same welding process parameters, the heat-affected zone of a 0mm gap weld is less than 1mm. Upper bainite is found in the 1mm weld gap structure. In the two gap cases, the residual stress on the lower surface is larger than that on the upper surface, and the residual stress in the 1mm weld gap is larger. The weldability of 0mm weld gap is better than 1mm.

scholarly journals Shielded Metal Arc and Thermite Welding Effect to Residual Stress, Hardness and Crack of R54-Rail Weld Joint

2020 ◽  
Vol 55 (4) ◽  
Author(s):  
Yurianto ◽  
Gunawan Dwi Haryadi ◽  
Sri Nugroho ◽  
Sulardjaka ◽  
Susilo Adi Widayanto
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Welded Joints ◽  
Arc Welding ◽  
Welding Process ◽  
Shielded Metal Arc Welding ◽  
Metal Arc Welding ◽  
Crack Susceptibility

The heating and cooling at the end of the welding process can cause residual stresses that are permanent and remain in the welded joint. This study aims to evaluate the magnitude and direction of residual stresses on the base metal and heat-affected zone of rail joints welded by the manual shielded metal arc and thermite welding. This research supports the feasibility of welding for rail. The material used in this study is the R-54 rail type, and the procedure used two rail samples of one meter long each, welded using manual shielded metal arc welding and thermite welding. The base metal and heat-affected zone of the welded joints were scanned with neutron ray diffraction. The scan produces a spectrum pattern and reveals the direction of the residual stress along with it. We found the strain value contained in both types of welded joints by looking at the microstrain values, which we obtained using the Bragg equation. The results show that the magnitude and direction of the residual stress produced by manual shielded metal arc welding and thermite welding are not the same. Thermite welding produces lower residual stress (lower crack susceptibility) than manual shielded metal arc welding. The melt's freezing starts from the edge to the center of the weld to create random residual stresses. The residual stress results of both the manual shielded metal arc welding and thermite welding are still below the yield strength of the base metal.

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