Review of Welding Residual Stress Stiffening Effect on Vibrational Characteristics of Structures Using Damage Approach and Vibratory Stress Relief Implementation

2017 ◽  
Author(s):  
AmirHossein MajidiRad ◽  
Yimesker Yihun
Keyword(s):  
Residual Stress ◽  
Modal Analysis ◽  
Structural Integrity ◽  
Material Selection ◽  
Welding Process ◽  
Stress Relief ◽  
Welding Residual Stress ◽  
Welded Structure ◽  
Welding Procedure

There is a huge amount of research and study on the quality, parameter manipulation, material selection etc. of welding to develop optimized results for specific applications. To have a profound understanding of the process, and to investigate and verify various parameters which affect the quality of the welding process, experts use analytical, numerical and experimental methods. The major concern regarding the welding procedure is welding defect, which can affect the integrity of the welded structure. Various nondestructive structural health monitoring methods and modal analysis techniques have been employed to study and improve the strength and quality of the welded structure. Modal analysis is one of the most accurate and commercial techniques to track down the damage within the structures. It uses natural frequency, damping factors and modal shapes to observe the structural and material defects in details. There have been noticeable developments in this area and lots of studies have been conducted applying this technique to put welding procedure under rigorous scrutiny to improve its efficiency. While modal analysis is a tool to identify structural integrity of the components, vibration can affect the nature of the metal and change the mechanical properties in some cases. Mechanical vibration and Ultrasonic as low and high frequency oscillations respectively, are able to change the microstructure of the structures so that dislocations move, hence the stress trapped within will redistribute. This redistribution can lead to residual stress reduction up to a level. In this review paper, all remarks above are considered, defined and accurately studied through various cases in order to address different application of vibratory stress relief and recent achievement in this field.

Numerical Analysis of Residual Stresses in Hyperbaric Welding

2012 ◽  
Author(s):  
Xiaobo Ren ◽  
Odd M. Akselsen ◽  
Sigmund K. Ås ◽  
Bård Nyhus
Keyword(s):  
Residual Stress ◽  
Numerical Analysis ◽  
Residual Stresses ◽  
Pressure Range ◽  
Structural Integrity ◽  
Sea Water ◽  
Welding Residual Stress ◽  
Transformation Plasticity ◽  
Micro Structure ◽  
Welding Procedure

Hyperbaric welding residual stress is one of the main concerns for deep water operation. This study presents the numerical investigation of residual stresses in hyperbaric welding by using WeldsimS code. The pressure range investigated in this study is from 3 to 35 bar, which corresponds to 30 to 350 msw (Meters of Sea Water). Experiments results indicate that the welding procedure might be significantly influenced within the pressure range studied. A 2D axisymmetric model has been considered in this study to simulate circumferential welding of a pipe. Phase transformations and transformation plasticity during the welding procedure have been taken into account. The main aim of the study is to predict the hyperbaric welding residual stresses. The temperature evolution and the micro-structure were also studied. Results show that residual stresses induced by hyperbaric welding are significant within the pressure range investigated, which should be assessed for the sake of structural integrity.

A Study of the Effect of Hardening Model in the Prediction of Welding Residual Stress

2012 ◽  
Author(s):  
Martina M. Joosten ◽  
Martin S. Gallegillo
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Structural Integrity ◽  
Kinematic Hardening ◽  
Welding Process ◽  
Cyclic Hardening ◽  
Welding Residual Stress ◽  
Isotropic Hardening ◽  
Hardening Models ◽  
Set Up

The presence of residual stresses can significantly affect the performance of manufactured products. The welding process is one of the most common causes of large tensile residual stresses, which may contribute to failure by brittle fracture or cause other forms of failure such as damage by corrosion and creep. Welding is a widely used method of fabrication and it can generate high levels of residual stress over significant proportions of the thickness of a component. In order to study the effect of material characterisation on computer based predictions of welding residual stresses, the presented work was carried out as part of the European Network on Neutron Techniques Standardisation for Structural Integrity (NeT). Within the NeT, a task group is investigating a three-pass Tungsten Inert Gas (TIG) weld benchmark. The three-pass specimen offers the possibility of examining the cyclic hardening and annealing behaviour of the weld metal and heat affected zone. A 3D model of the benchmark NeT problem was set up using ABAQUS v6.9.1 and validated against measurements. This paper presents the finite element work. Future papers from the NeT shall present experimental measurements. Different hardening models were considered in order to study their effect on the residual stresses. The different hardening models were isotropic hardening, linear and nonlinear kinematic hardening and combinations of these. Also the effect of annealing on the hardening behaviour is studied. Finally, the results of the simulations are compared to residual stress distributions as given in several standards.

scholarly journals Numerical Investigation of Welding Residual Stress Field and its Behaviour under Multiaxial Loading in Tubular Joints

2014 ◽  
Vol 996 ◽  
pp. 788-793
Author(s):  
Kimiya Hemmesi ◽  
Majid Farajian ◽  
Dieter Siegele
Keyword(s):  
Residual Stress ◽  
Yield Strength ◽  
Residual Stresses ◽  
Structural Integrity ◽  
Weld Zone ◽  
Welding Residual Stress ◽  
Multiaxial Loading ◽  
Residual Stress Field ◽  
Tubular Joints ◽  
Welded Structure

The lack of clarities in estimating the residual stress threat to the structural integrity has led to conservative assumptions in the current design of welds. The complexities become more in the case of multiaxial loading of welded structure, considering fracture or fatigue. To what extent the residual stresses influence the performance of a welded structure, depends on how stable they are under service loads. Finite element analyses are used here to describe the development of welding residual stresses in tubular joints and their relaxation under multiaxial loading. It is observed that the effect of the torsion load is more significant than the effect of tension load in releasing of the residual stresses. For pure tensile loading, the relaxation of the residual stresses are negligible as long as the applied load is lower than 50% of the yield strength of the material. For a combined tension-torsion loading of 75% of the yield strength, the residual stresses are almost completely released, and in the weld zone they become compressive.

A Study on Numerical Analysis and Residual Stress Evaluation of Welded Joint

2008 ◽  
Vol 575-578 ◽  
pp. 799-804
Author(s):  
Sun Chul Huh
Keyword(s):  
Residual Stress ◽  
Rapid Heating ◽  
Welding Process ◽  
Welding Residual Stress ◽  
Welding Distortion ◽  
Light Weight ◽  
Element Analysis ◽  
Welding Condition ◽  
Heating And Cooling ◽  
Welded Structure

The structures of existing wings had holes for light weight and plates and frames were fixed with rivets or screws, thus, there were difficulties and limits in light weight. Welding process generates distortion and residual stress in the welding due to rapid heating and cooling. Welding distortion and residual in the welded structure result in many troubles such as dimensional inaccuracies in assembling and safety problem during service. The accurate prediction of welding residual stress is thus very important to improve the quality of welding and find the way to reduce itself. In this study, an improvement was made in current joint methods through EB welding and laser welding for light weight of wings and welding strength was measured through strength test. In addition, finite element analysis was performed for welding process so as to induce optimum welding condition.

scholarly journals The effect of laser stitch welding residual stress on the dynamic behaviour of thin steel structure

2019 ◽  
Vol 13 (4) ◽  
pp. 5780-5790
Author(s):  
M. A. S. Aziz Shah ◽  
M. A. Yunus ◽  
M. N. Abdul Rani ◽  
A. M. Saman ◽  
M. S. M. Sani ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Welding Process ◽  
Steel Structure ◽  
Welding Residual Stress ◽  
Mode Shapes ◽  
Finite Element Models ◽  
Welded Structures ◽  
Welded Structure ◽  
Thin Steel

Laser stitch welding is one of the most reliable and efficient permanent metal joining processes in the automotive industry, particularly in the manufacturing of a car body-in-white (BIW). It is widely known that this welding process induces the generation of residual stresses that can influence the dynamic behaviours of welded structures. In order to accurately predict the dynamic behaviours of these welded structures, it is important to experimentally understand the influence of residual stress. Therefore, this study addresses the finite element modelling method of thin steel welded structures with and without the influences of residual stress in order to identify its effect towards dynamic behaviours. The finite element models of thin steel welded structures are developed by employing the area contact model (ACM2) format element connector.  The accuracy of the finite element models is then compared in terms of natural frequencies and mode shapes with the experimental counterparts. The dynamic behaviours of the measured structure are obtained using an impact hammer with free-free boundary conditions. The results demonstrate the importance of considering the influence of laser stitch welding residual stress in predicting the dynamic behaviours of thin steel welded structure.    

Numerical simulation of the effect of ultrasonic impact treatment on welding residual stress

2021 ◽  
pp. 2150175
Author(s):  
Tao Mo ◽  
Jingqing Chen ◽  
Pengju Zhang ◽  
Wenqian Bai ◽  
Xiao Mu ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Compressive Stress ◽  
Welded Joints ◽  
Welding Process ◽  
Residual Compressive Stress ◽  
Welding Residual Stress ◽  
304 Stainless Steel ◽  
Residual Tensile Stress ◽  
Ultrasonic Impact Treatment

Ultrasonic impact treatment (UIT) is an effective method that has been widely applied in welding structure to improve the fatigue properties of materials. It combines mechanical impact and ultrasonic vibration to produce plastic deformation on the weld joints surface, which introduces beneficial compressive residual stress distribution. To evaluate the effect of UIT technology on alleviating the residual stress of welded joints, a novel numerical analysis method based on the inherent strain theory is proposed to simulate the stress superposition of welding and subsequent UIT process of 304 stainless steel. Meanwhile, the experiment according to the process was carried out to verify the simulation of residual stress values before and after UIT. By the results, optimization of UIT application could effectively reduce the residual stress concentration after welding process. Residual tensile stress of welded joints after UIT is transformed into residual compressive stress. UIT formed a residual compressive stress layer with a thickness of about 0.13 mm on the plate. The numerical simulation results are consistent with the experimental results. The work in this paper could provide theoretical basis and technical support for the reasonable evaluation of the ultrasonic impact on residual stress elimination and mechanical properties improvement of welded joints.

scholarly journals Evolution of Welding Residual Stresses within Cladding and Substrate during Electroslag Strip Cladding

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4126
Author(s):  
Mu Qin ◽  
Guangxu Cheng ◽  
Qing Li ◽  
Jianxiao Zhang
Keyword(s):  
Residual Stress ◽  
Classical Model ◽  
Stress Gradient ◽  
Welding Process ◽  
Welding Residual Stress ◽  
Oil Refining ◽  
Substrate Thickness ◽  
Preheat Temperature ◽  
Cladding Layer ◽  
Hydrogenation Reactor

Hydrogenation reactors are important oil-refining equipment that operate in high-temperature and high-pressure hydrogen environments and are commonly composed of 2.25Cr–1Mo–0.25V steel. For a hydrogenation reactor with a plate-welding structure, the processes and effects of welding residual stress (WRS) are very complicated due to the complexity of the welding structure. These complex welding residual stress distributions affect the service life of the equipment. This study investigates the evolution of welding residual stress during weld-overlay cladding for hydrogenation reactors using the finite element method (FEM). A blind hole method is applied to verify the proposed model. Unlike the classical model, WRS distribution in a cladding/substrate system in this study was found to be divided into three regions: the cladding layer, the stress-affected layer (SAL), and the substrate in this study. The SAL is defined as region coupling affected by the stresses of the cladding layer and substrate at the same time. The evolution of residual stress in these three regions was thoroughly analyzed in three steps with respect to the plastic-strain state of the SAL. Residual stress was rapidly generated in Stage 1, reaching about −440 MPa compression stress in the SAL region at the end of this stage after 2.5 s. After cooling for 154 s, at the end of Stage 2, the WRS distribution was fundamentally shaped except for in the cladding layer. The interface between the cladding layer and substrate is the most heavily damaged region due to the severe stress gradient and drastic change in WRS during the welding process. The effects of substrate thickness and preheat temperature were evaluated. The final WRS in the cladding layer first increased with the increase in substrate thickness, and then started to decline when substrate thickness reached a large-enough value. WRS magnitudes in the substrate and SAL decreased with the increase in preheat temperature and substrate thickness. Compressive WRS in the cladding layer, on the other hand, increased with the increase in preheat temperature.

Development of an Effective ASME IX Welding Procedure Qualification Program for Pipeline Facility and Fabrication Welding

2016 ◽  
Author(s):  
Junfang Lu ◽  
Bob Huntley ◽  
Luke Ludwig
Keyword(s):  
Oil And Gas ◽  
Material Selection ◽  
Base Material ◽  
Welding Process ◽  
Notch Toughness ◽  
Essential Variable ◽  
Performance Qualification ◽  
Pipeline Welding ◽  
Welding Consumable ◽  
Welding Procedure

For cross country pipeline welding in Canada, welding procedures shall be qualified in accordance with the requirements of CSA Z662 Oil and Gas Pipeline Systems. For pipeline facility and fabrication welding on systems designed in accordance with CSA Z662 or ASME B31.4, welding procedures qualified in accordance with the requirements of ASME Boiler & Pressure Vessel Code Section IX are permitted and generally preferred. Welding procedures qualified in accordance with ASME IX provide advantages for pipeline facility and fabrication applications as a result of the flexibility achieved through the larger essential variable ranges. The resulting welding procedures have broader coverage on material thickness, diameter, joint configuration and welding positions. Similarly, ASME IX is more flexible on welder performance qualification requirements and accordingly a welder will have wider range of performance qualifications. When applied correctly, the use of ASME IX welding procedures often means significantly fewer welding procedures and welder performance qualifications are required for a given scope of work. Even though ASME IX qualified welding procedures have been widely used in pipeline facility and fabrication welding, it is not well understood on how to qualify the welding procedures in accordance with ASME IX and meet the additional requirements of the governing code or standard such as CSA Z662 in Canada. One significant consideration is that ASME IX refers to the construction code for the applicability of notch toughness requirements for welding procedure qualification, yet CSA Z662 and ASME B31.4 are both silent on notch toughness requirements for welding procedure qualification. This paper explains one preferred method to establish and develop an effective ASME IX welding procedure qualification program for pipeline facility and fabrication welding while ensuring suitability for use and appropriate notch toughness requirements. The paper discusses topics such as base material selection, welding process, welding consumable consideration and weld test acceptance criteria.

Evaluation of Welding Residual Stress Based on Temper Bead Welding Technique

2011 ◽  
Vol 418-420 ◽  
pp. 1208-1212 ◽  
Author(s):  
Xian Shi ◽  
Yi Liang Zhang ◽  
Jian Ping Zhao ◽  
Rui Bin Gou
Keyword(s):  
Residual Stress ◽  
Engineering Application ◽  
Maximum Principal Stress ◽  
Welding Residual Stress ◽  
Ray Method ◽  
Butt Weld ◽  
Welding Procedure ◽  
16Mn Steel ◽  
Better Than ◽  
Welding Technique

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.

Instrumented-Indentation-Technique-Based Residual Stress Characterization for Weldment of Structural Components

2006 ◽  
Author(s):  
Dongil Kwon ◽  
Jung-Suk Lee ◽  
Kwang-Ho Kim ◽  
Afshin Motarjemi ◽  
Julian Speck
Keyword(s):  
Residual Stress ◽  
Welding Process ◽  
Indentation Load ◽  
Welding Residual Stress ◽  
Hole Drilling ◽  
Structural Components ◽  
Instrumented Indentation ◽  
Indentation Technique ◽  
Safety And Reliability ◽  
Depth Curve

The weld joints in structural components have long been considered important sites for safety and reliability assessment. In particular, the residual stress in piping weldments induced by the welding process must be evaluated accurately before and during service. This study reports an indentation technique for evaluating welding residual stress nondestructively. Indentation load-depth curves were found to shift with the magnitude and direction of the residual stress. Nevertheless, contact depths in the stress-free and stressed states were constant at a specific indentation load. This means that residual stress induces additional load to keep contact depth constant at the same load. By taking these phenomena into account, welding residual stress was obtained directly from the indentation load-depth curve. In addition, the results were compared with values from the conventional hole-drilling and saw-cutting method.

Sign in / Sign up

Export Citation Format

Share Document