Sequential Transient Numerical Simulation of Inertia Friction Welding Process

2008 ◽  
Author(s):  
Medhat Awad El-Hadek ◽  
Mohammad S. Davoud
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Friction Welding ◽  
Welding Process ◽  
Transient Temperature ◽  
Inertia Friction Welding ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Full Field ◽  
Welding Processes

Inertia friction welding processes often generate substantial residual stresses due to the heterogeneous temperature distribution during the welding process. The residual stresses which are the results of incompatible elastic and plastic deformations in weldment will alter the performance of welded structures. In this study, three-dimensional (3D) finite element analysis has been performed to analyze the coupled thermo-mechanical problem of inertia friction welding of a hollow cylinder. The analyses include the effect of conduction and convection heat transfer in conjunction with the angular velocity and the thrust pressure. The results include joint deformation and a full-field view of the residual stress field and the transient temperature distribution field in the weldment. The shape of deformation matches the experimental results reported in the literature. The residual stresses in the heat-affected zone have a high magnitude but comparatively are smaller than the yield strength of the material.

Evolution of Temperature Distribution and Microstructure in Multipass Welded AISI 321 Stainless Steel Plates With Different Thicknesses

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Soheil Nakhodchi ◽  
Ali Shokuhfar ◽  
Saleh Akbari Iraj ◽  
Brian G. Thomas
Keyword(s):  
Stainless Steel ◽  
Temperature Distribution ◽  
Residual Stresses ◽  
Arc Welding ◽  
Welding Process ◽  
Steel Plates ◽  
Temperature History ◽  
Transient Temperature ◽  
Multipass Welding ◽  
Aisi 321

Prediction of temperature distribution, microstructure, and residual stresses generated during the welding process is crucial for the design and assessment of welded structures. In the multipass welding process of parts with different thicknesses, temperature distribution, microstructure, and residual stresses vary during each weld pass and from one part to another. This complicates the welding process and its analysis. In this paper, the evolution of temperature distribution and the microstructure generated during the multipass welding of AISI 321 stainless steel plates were studied numerically and experimentally. Experimental work involved designing and manufacturing benchmark specimens, performing the welding, measuring the transient temperature history, and finally observing and evaluating the microstructure. Benchmark specimens were made of corrosion-resistant AISI 321 stainless steel plates with different thicknesses of 6 mm and 10 mm. The welding process consisted of three welding passes of two shielded metal arc welding (SMAW) process and one gas tungsten arc welding (GTAW) process. Finite element (FE) models were developed using the DFLUX subroutine to model the moving heat source and two different approaches for thermal boundary conditions were evaluated using FILM subroutines. The DFLUX and FILM subroutines are presented for educational purposes, as well as a procedure for their verification.

scholarly journals NUMERICAL SIMULATION ON JOINING OF CERAMICS WITH METAL BY FRICTION WELDING TECHNIQUE

2013 ◽  
Vol 22 ◽  
pp. 190-195 ◽  
Author(s):  
N. RAJESH JESUDOSS HYNES ◽  
P. NAGARAJ ◽  
S. JOSHUA BASIL
Keyword(s):  
Numerical Simulation ◽  
Thermal Analysis ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Temperature Distribution ◽  
Friction Welding ◽  
Transient Liquid Phase ◽  
Sheet Thickness ◽  
Welding Process ◽  
Element Analysis

The joining of ceramic and metals can be done by different techniques such as ultrasonic joining, brazing, transient liquid phase diffusion bonding, and friction welding. Friction Welding is a solid state joining process that generates heat through mechanical friction between a moving workpiece and a stationary component. In this article, numerical simulation on thermal analysis of friction welded ceramic/metal joint has been carried out by using Finite Element Analysis (FEA) software. The finite element analysis helps in better understanding of the friction welding process of joining ceramics with metals and it is important to calculate temperature and stress fields during the welding process. Based on the obtained temperature distribution the graphs were plotted between the lengths of the joint corresponding to the temperatures. To increase the wettability, aluminium sheet was used as an interlayer. Hence, numerical simulation of friction welding process is done by varying the interlayer sheet thickness. Transient thermal analysis had been carried out for each cases and temperature distribution was studied. From the simulation studies, it is found that the increase in interlayer thickness reduces the heat affected zone and eventually improves the joint efficiency of alumina/aluminum alloy joints.

Influence of Initial and Welding Residual Stresses on Low Cycle Fatigue and Ratcheting Response Simulations of Elbows

2017 ◽  
Author(s):  
Nazrul Islam ◽  
Tasnim Hassan
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Low Cycle Fatigue ◽  
Simulation Models ◽  
Cycle Fatigue ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Girth Welding ◽  
Stress States ◽  
Welding Processes

Earlier studies [1] showed that the ANSYS software package customized with an advanced rate-independent constitutive model was unable to simulate some of the low-cycle fatigue responses of elbow components. Hence, simulations are performed to investigate the influence of manufacturing and welding residual stresses on elbow low-cycle fatigue responses. The sequentially coupled thermo-mechanical finite element analysis is performed to determine the initial residual stress states in elbows due to the elbow manufacturing processes and welding of elbows to straight pipes. Real-time girth-welding processes are taken into account to simulate the welding induced residual stress field. Incorporating these initial residual stresses in the computations, low-cycle fatigue and strain ratcheting responses are simulated by ANSYS. The simulation responses demonstrate that the influence of manufacturing and welding residual stresses in elbows on its low-cycle fatigue responses is negligible. Hence, the question remains what is missing in the simulation models that some of the elbow low-cycle fatigue responses cannot be simulated.

Residual Stresses Evaluation on Radial Friction Welded Joints

2005 ◽  
Author(s):  
Rosa Irene Terra Pinto ◽  
Telmo Roberto Strohaecker
Keyword(s):  
Residual Stresses ◽  
Friction Welding ◽  
Deformation Gradient ◽  
Welding Process ◽  
Hole Drilling ◽  
Welding Parameters ◽  
Hole Drilling Method ◽  
Joint Quality ◽  
Welding Processes

The Radial Friction Welding (RFW) is a solid-state welding process in which two long elements of several metallic alloys can be joined, without the occurrence of common problems to the conventional welding processes that include fusion. During friction welding the temperature evolution is directly related with the deformation gradient, and these fields govern the joint properties. In this work, the finite element method was used to solve the full coupled termomechanical problem in order to determine the deformation and the stress fields and the variation of the temperature during RFW process. The simulation of the RFW process permitted to establish the influence of the welding parameters, like rotation and approximation speed, on the joint quality. Furthermore, the knowledge of the temperature gradient and cooling rates allowed the prediction of the resulting microestruture and determination of the level of residual stresses of the joint. To verify the analytical results the determination of the residual stresses was accomplished by the hole drilling method in several points along the perimeter of two welded workpieces.

Finite Element Modeling of GMAW Process: Evolution and Formation of Residual Stresses Upon Cooling

2004 ◽  
Author(s):  
Mohammad S. Davoud ◽  
Xiaomin Deng
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Arc Welding ◽  
Three Dimensional ◽  
Residual Stress Field ◽  
Full Field ◽  
Elastic And Plastic Deformations ◽  
2D And 3D ◽  
Welding Processes ◽  
Field View

Fusion arc welding processes often generate substantial residual stresses, which may alter the performance of welded structures. Residual stresses are the results of incompatible elastic and plastic deformations in a body. Destructive techniques are generally used to experimentally determine residual stresses. Employment of these methods would not often be possible or practical in industry. In this study, three-dimensional (3D) and two-dimensional (2D) finite element simulations and experimental work have been performed to analyze the thermomechanical problem of GMAW and to obtain a full-field view of the residual stress field. One of the purposes of this study is to examine the formation of residual stresses upon cooling of a weldment. Comparisons of the results of 2D and 3D finite element models reveal many three-dimensional features in the thermomechanical problem of GMAW. The magnitude of longitudinal residual stresses obtained from the 2D model, however, compares well with the results obtained from the 3D model.

scholarly journals Thermal and structural modelling of arc welding processes: A literature review

2019 ◽  
Vol 52 (7-8) ◽  
pp. 955-969 ◽  
Author(s):  
Hitesh Arora ◽  
Rupinder Singh ◽  
Gurinder Singh Brar
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Arc Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Inert Gas ◽  
Welding Distortion ◽  
Structural Modelling ◽  
Welding Processes

This paper presents a state-of-the-art critical review of the thermal and structural modelling of the arc welding process. During the welding process, high temperature in the welding zone leads to generation of unwanted residual stresses and results in weld distortion. Measurement of the temperature distribution was a key issue and challenge in the past decade. Thermomechanical analysis is among the best-known techniques to simulate and investigate the temperature distribution, welding distortion and residual stresses in the weld zone. The main emphasis of this review is the thermal and structural modelling of welding processes and the measurement of welding residual stresses using different techniques. The study also provides information about the various types of heat sources and models used to predict the weld bead characteristics and thermomechanical analysis for different welding processes such as tungsten inert gas welding, metal inert gas welding and shielded metal arc welding.

scholarly journals Improving Fatigue Performance of Alumino-Thermic Rail Welds

2010 ◽  
Vol 24-25 ◽  
pp. 305-310
Author(s):  
M. Jezzini-Aouad ◽  
Patrick Flahaut ◽  
Saïd Hariri ◽  
D. Zakrzewski ◽  
L. Winiar
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welding Process ◽  
Thermal Conditions ◽  
Type A ◽  
Fatigue Tests ◽  
Traffic Density ◽  
Residual Stress Field ◽  
Element Analysis ◽  
The Web

Rail transport development offers economic and ecological interests. Nevertheless, it requires heavy investments in rolling material and infrastructure. To be competitive, this transportation means must rely on safe and reliable infrastructure, which requires optimization of all implemented techniques and structure. Rail thermite (or alumino-thermic) welding is widely used within the railway industry for in-track welding during re-rail and defect replacement. The process provides numerous advantages against other welding technology commonly used. Obviously, future demands on train traffic are heavier axle loads, higher train speeds and increased traffic density. Thus, a new enhanced weld should be developed to prevent accidents due to fracture of welds and to lower maintenance costs. In order to improve such assembly process, a detailed metallurgical study coupled to a thermomechanical modeling of the phenomena involved in the rail thermite welding process is carried out. Obtained data enables us to develop a new improved alumino-thermic weld (type A). This joint is made by modifying the routinely specified procedure (type B) used in a railway rail by a standard gap alumino-thermic weld. Joints of type A and B are tested and compared. Based on experimental temperature measurements, a finite element analysis is used to calculate the thermal residual stresses induced. Besides, experimental investigation was carried out in order to validate the numerical model. Hence, X-Ray diffraction has been used to map the residual stress field that is generated in welded rail of types A and B. In the vicinity of the weld, the residual stress patterns depend on the thermal conditions during welding. Their effect on fatigue crack growth in rail welds is studied. In the web region, both longitudinal and vertical components of residual stresses are tensile, which increases the susceptibility of that region to crack initiation and propagation from internal material defects. Indeed, weld fracture in track initiates at the web fillet. Thus, to be closer to real issue, fatigue tests specimens has been defined within the split-web area. Fatigue tests was performed on the defined specimens, welded by conventional and improved processes and obtained results adjudicates on the new advances.

Numerical Simulation of Temperature Field and Residual Stress in Multi-Pass Welds in 2.25Cr-1Mo-0.25V Steel Plate and Comparison With Experimental Measurements

2017 ◽  
Author(s):  
Mu Qin ◽  
Guangxu Cheng ◽  
Zaoxiao Zhang ◽  
Qing Li ◽  
Jianxiao Zhang
Keyword(s):  
Residual Stress ◽  
Temperature Distribution ◽  
Stress Distribution ◽  
Residual Stresses ◽  
Pressure Vessels ◽  
Residual Stress Distribution ◽  
Bottom Surface ◽  
Transient Temperature ◽  
Transient Temperature Distribution ◽  
Welding Processes

The 2.25Cr-1Mo-0.25V steels are widely used in the petroleum chemical industry for the manufacturing of pressure vessels. The multi-pass welding is a critical type of fabrication in hydrogenation reactor. However, very complicated residual stresses could be generated during the multi-pass welding process. The presence of residual stresses could have significant influence on the performance of welded product. In the present work, the transient temperature distribution and residual stress distribution in welding of 2.25Cr-1Mo-0.25V steel are analyzed by using numerical method. An uncoupled thermal-mechanical two-dimensional (2-D) FEM is proposed under the ABAQUS environment. The transient temperature distribution and the residual stress distribution during the welding processes are determined through the finite element method. A group of experiments by using the blind-hole method have been conducted to validate the numerical results. The results of 2-D model agree well with the experiment. The result shows that the maximum welding stress generated at heat affected zone (HAZ) both at the top and bottom surface whether to transverse stress or longitudinal stress.

FEM Prediction of Welding Residual Stresses and Temperature Fields in Butt and T-Welded Joints

2011 ◽  
Vol 418-420 ◽  
pp. 1486-1493
Author(s):  
Afsaneh Razavi ◽  
Fatemeh Hafezi ◽  
Hossein Farrahi
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joints ◽  
Parametric Design ◽  
Weld Zone ◽  
Three Dimensional ◽  
Welding Process ◽  
Temperature Fields ◽  
Residual Stress Field ◽  
Welding Processes

Residual stresses resulted from localized non-uniform heating and subsequent cooling during welding processes enact an important role in the formation of cracks and welding distortions and have severe effect on performance of welded joints. The present research performs a three dimensional transient thermo Elasto-plastic analysis using finite element technique to simulate welding process. Welding simulation procedure is developed using the parametric design language of commercial code ANSYS for single pass T and butt welded joints. The procedure verified with predicted residual stress field found in literature to confirm the accuracy of the method. The material of the weld metal, HAZ and the base metal are assumed to be the same. With regards to high temperature gradient in weld zone, temperature dependant thermal and mechanical properties have been incorporated in the simulation. Also in this work the technique of element birth and death was employed to simulate moving heat source and the weld filler variation with time. Temperature and residual stress fields were discussed.

Numerical simulation of inertia friction welding process of GH4169 alloy

2004 ◽  
Vol 120 ◽  
pp. 681-687
Author(s):  
Zhang Liwen ◽  
Liu Chengdong ◽  
Qi Shaoan ◽  
Yu Yongsi ◽  
Zhu Wenhui ◽  
...  
Keyword(s):  
Temperature Field ◽  
Friction Welding ◽  
Welding Process ◽  
Experimental Result ◽  
Transient Temperature ◽  
Inertia Friction Welding ◽  
Fem Model ◽  
Finite Element Software ◽  
Transient Temperature Field ◽  
Temperature Filed

Friction welding is a solid state welding technology with good quality and high automation. It has been widely used in many industry fields especially in automobile and aerospace industry. Because of the characters of less process parameters and high automation, inertia friction welding is popular in many fields. In this paper, a 2-D thermo-mechanical FEM model was developed to simulate inertia welding process. In this model, the temperature dependency of the thermal and mechanical properties of material was considered. The finite-element software MSC.Marc was used to calculate the temperature field, stress field and strain field during inertia friction welding process. The transient temperature field and the deformation of GH4169 superalloy during inertia friction welding process were predicted. The temperature filed during inertia friction welding process was measured by means of thermocouples. The calculated temperature filed is in good agreement with the experimental result.

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