Preliminary Finite Element assessment of residual stresses in dissimilar AA6082-S355 butt welded joints produced with the Hybrid Metal Extrusion and Bonding (HYB) technique

Welding is one of the most used joining methods in the ship industry. However, residual stresses are induced in the welded joints due to the rapid heating and cooling leading to inhomogenously distributed dimensional changes and non-uniform plastic and thermal strains. A number of factors, such as welding speed, boundary conditions, weld geometry, weld thickness, welding current/voltage, number of weld passes, pre-/post-heating etc, influence the residual stress distribution. The main aim of this work is to estimate the residual stresses in welded joints through finite element analysis and to investigate the effects of boundary conditions, welding speed and plate thickness on through the thickness/surface distributions of residual stresses. The welding process is simulated using 3D Finite element model in ABAQUS FE software in two steps: 1. Transient thermal analysis and 2. Quasi-static thermo-elasto-plastic analysis. The normal residual stresses along and across the weld in the weld tow region are found to be significant with nonlinear distribution. The residual stresses increase with the increase in the thickness of the plates being welded. The nature of the normal residual stress along the weld is found to be tensile-compressive-tensile and the nature of normal residual stress across the weld is found to be tensile along the thickness direction.

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Residual Stress and Strain Responses of Welded Piping Joints Under Low-Cycle Fatigue Loading

Volume 1: Codes and Standards ◽

10.1115/pvp2009-77813 ◽

2009 ◽

Author(s):

Pei-Yuan Cheng ◽

Tasnim Hassan

Keyword(s):

Residual Stress ◽

Finite Element ◽

Residual Stresses ◽

Fatigue Failure ◽

Welded Joints ◽

Low Cycle Fatigue ◽

Fatigue Cracks ◽

Stress And Strain ◽

Weld Toe ◽

Strain Responses

It is well known that residual stress of welded joints influence their fatigue lives. This influence of residual stress is manifested through strain ratcheting response at the weld toe. Among many other reasons, strain ratcheting at the weld toe is anticipated to be a reason of many premature fatigue failure of welded joints. Hence, accurate simulations of weld toe residual stress and strain responses are essential for fatigue life simulation of welded joints. This paper presents results form an ongoing study on fatigue failure of welded piping joints. A modeling scheme for simulating weld toe residual stress and strain response is developed. Uncoupled, thermo-mechanical, finite element analyses are employed for imitating the welding procedure, and thereby simulating the temperature history during welding and initial residual stresses. Simulated residual stresses are validated by comparing against the measured residual stresses. Finite element simulations indicate that both residual stress and resulting strain responses near the weld toe are the key factors in inducing fatigue cracks at the weld toe. Research needs in revealing the fatigue failure mechanisms at the weld toe are discussed.

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Residual Stresses with Time-Independent Cyclic Plasticity in Finite Element Analysis of Welded Joints

Metals ◽

10.3390/met7040136 ◽

2017 ◽

Vol 7 (4) ◽

pp. 136 ◽

Cited By ~ 13

Author(s):

Ruben Lostado Lorza ◽

Marina Corral Bobadilla ◽

María Martínez Calvo ◽

Pedro Villanueva Roldán

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Residual Stresses ◽

Welded Joints ◽

Cyclic Plasticity ◽

Element Analysis

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Finite Element Analysis of Residual Stresses on Butt Welded Joints

Volume 4: Fatigue and Fracture, Heat Transfer, Internal Combustion Engines, Manufacturing, and Technology and Society ◽

10.1115/esda2006-95125 ◽

2006 ◽

Cited By ~ 2

Author(s):

Enrico Armentani ◽

Renato Esposito ◽

Raffaele Sepe

Keyword(s):

Finite Element ◽

Residual Stresses ◽

Fusion Zone ◽

Welded Joints ◽

High Strength Steels ◽

High Strength ◽

Heat Of Fusion ◽

Temperature Dependent ◽

Element Analysis ◽

Welding Processes

Localized heating during welding, followed by rapid cooling, usually generates residual stresses in the weld and in the base metal. Residual stresses in welding processes give significant problems in the accurate manufacture of structures because those stresses heavily induce the formation of cracks in the fusion zone in high strength steels. Therefore, estimating the magnitude and distribution of welding residual stresses and characterizing the effects of certain welding conditions on the residual stresses are deemed necessary. In this work, residual stresses and distortions on butt welded joints are numerically evaluated by means of finite element method. The FE analysis allows to highlight and evaluate the stress field and his gradient around the fusion zone of welded joints, higher than any other located in the surrounding area. Temperature-dependent material properties, welding velocity, external mechanism constraints, technique of ‘element birth and death’ and latent heat of fusion are also taken into account. Some numerical results are compared with experimental data showing a very good correlation.

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Finite Element Simulation of Temperature Distribution, Distortion and Residual Stresses of Dissimilar Welded Joints

Materials Today Proceedings ◽

10.1016/j.matpr.2018.02.167 ◽

2018 ◽

Vol 5 (5) ◽

pp. 11933-11940 ◽

Cited By ~ 3

Author(s):

K. Venkateswarlu ◽

P. Nanda Kumar ◽

P.S. RaviKumar

Keyword(s):

Finite Element ◽

Temperature Distribution ◽

Residual Stresses ◽

Finite Element Simulation ◽

Welded Joints ◽

Element Simulation

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Numerical Simulation of Residual Stress in the Glass-to-Metal Diffusion Seals

Materials Science Forum ◽

10.4028/www.scientific.net/msf.575-578.666 ◽

2008 ◽

Vol 575-578 ◽

pp. 666-671 ◽

Cited By ~ 4

Author(s):

Di Xu ◽

Xiang Ling

Keyword(s):

Numerical Simulation ◽

Residual Stress ◽

Finite Element ◽

Residual Stresses ◽

Welded Joints ◽

Thermal Power ◽

Diffusion Welding ◽

Finite Element Software ◽

Metal Diffusion ◽

Metal Seal

The glass-to-metal seals are widely used in the solar thermal power. When a glass-to-metal seal is cooled in the process of diffusion welding, the residual stresses are generated due to different thermal contraction between the two materials. The residual stresses built up along the interface near the end of the seal can induce welded joints to crack and decrease the fatigue intensity of the welded joints and thus are of technical importance. In order to obtain the residual stresses existed in the diffusion welded joints, the glass-to-metal vacuum diffusion sealing process were simulated by using finite element software ABAQUS. Furthermore, the influences of temperature, time, vacuum, and seal pressure on the strength of the glass-to-metal diffusion welding were analyzed. The optimization of the diffusion welding process parameter based on the simulation of the residual stress and analysis of the micro-structure and the macro-mechanical performance of the diffusion welded seals was carried out. The distribution of residual stress on the surface of the glass-to-metal joint caused by welding is measured by X-ray diffraction method, and compared with the result of the numerical simulation to prove the validation of the finite element model.

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