Finite Element Modeling of Hybrid Friction Diffusion Welding of Tube-Tubesheet Joints

2019 ◽  
Author(s):  
Fadi Al-Badour
Keyword(s):  
Finite Element ◽  
Carbon Steel ◽  
Flow Behavior ◽  
Welding Process ◽  
Element Model ◽  
Processing Parameters ◽  
Steel Tube ◽  
Diffusion Welding ◽  
Steel Shell ◽  
Element Analysis

Abstract Hybrid Friction Diffusion Bonding (HFDB) is a solid-state welding process that proved its capability of producing sound tube-tubesheet joints, but with limitations on tube thickness (up to 1mm) and tube-tubesheet materials. In the petrochemical industry, there is a great demand for the use of carbon steel shell and tube heat exchangers. To investigate the feasibility of HFDB techniques in joining thicker tube (i.e 2.1 mm) on tubesheet joint, a three-dimensional thermo-mechanical finite element model (FEM) was developed and solved using ABAQUS (commercial finite element analysis (FEA) software). The model was used to predict the temperature distribution and developed stresses during and after welding. The model considered temperature dependent material properties while Johnson-cook model was used to govern material plastic flow behavior. In this paper,19 mm (¾ in) ASTM 179 cold-drawn carbon steel tube into an ASTM A516 Grade 70 tubesheet joints was simulated. Results are validated based on temperature measurements, which was found in good agreement with experimental results. The developed model can be used to optimize processing parameters (i.e. tool rotational speed, dwell time “holding time”, and forging force.. etc) and study their effect on material flow and developed stresses.

A Comparison Between Three- and Two-Dimensional Thermal Finite Element Analysis of the Gas Metal Arc Welding Process

2003 ◽  
Author(s):  
Mohammad S. Davoud ◽  
Xiaomin Deng
Keyword(s):  
Finite Element ◽  
3D Model ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Element Model ◽  
Transient Temperature ◽  
Two Dimensional ◽  
Element Analysis ◽  
Cross Sectional ◽  
2D Model

Predictions of transient temperature distributions in welding can help the selection of welding process parameters that minimize residual stresses. A three-dimensional (3D) thermal finite element model of bead-on-plate gas metal are welding (GMAW) is presented and is used to evaluate a cross-sectional, two-dimensional (2D) counterpart model. While the thermomechanical problem of welding is 3D in nature, it is shown that the 2D model can provide temperature field predictions comparable to those of the 3D model, even though the 2D model tends to predict peak temperatures higher than those of the 3D model. Both types of model predictions are compared to welding test measurements.

Finite Element Analysis on Behavior of the Joint with Steel Tube Confined Concrete (STCC) Column to Reinforced Concrete Beam

2011 ◽  
Vol 243-249 ◽  
pp. 527-530 ◽  
Author(s):  
Wen Da Wang ◽  
Zhi Feng Guo ◽  
Yan Li Shi
Keyword(s):  
Finite Element ◽  
Mechanical Performance ◽  
Material Model ◽  
Element Model ◽  
Reinforced Concrete Beam ◽  
Steel Tube ◽  
Confined Concrete ◽  
Composite Joints ◽  
Element Analysis ◽  
Composite Joint

The steel tube confined concrete (STCC) column exhibits excellent mechanical performance. A 3-D finite element model (FEM) using ABAQUS was established to simulate the performance of the composite joints with STCC column and RC beam. Accurate material model, rational element type, and solution method were discussed. Some STCC columns and composite joints with concrete-filled steel tubular (CFST) column and STCC column were modeled based on the model, respectively. The results from FEM are good agreement with the test results. The mechanism of the composite joint was investigated based on the FEM.

Finite Element Analysis of Effects of Preheating and Postweld Heat Treatment on Residual Stress in Pipe Welding

2011 ◽  
Vol 314-316 ◽  
pp. 428-431 ◽  
Author(s):  
Hui Du ◽  
Dong Po Wang ◽  
Chun Xiu Liu ◽  
Hai Zhang
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Finite Element ◽  
Stress Distribution ◽  
Welding Process ◽  
Postweld Heat Treatment ◽  
Element Model ◽  
Element Analysis ◽  
Pipe Welding ◽  
Postweld Heat

To simulate preheating and postweld heat treatment of Q345 steel pipe welding, the finite element model was established. The welding process was simulated by method of the ANSYS element birth and death technique. In this paper, to obtain the distribution of the temperature field and stress field in different situations, preheating processes with two different values of temperature and postweld heat treatment process were simulated respectively. The results show that preheating can homogenize residual stress distribution of the weldment and decrease the residual stress. The heat treatment reduces the residual stress in inner and outer walls by 24% and 70% respectively and the stress distribution is more even and stress concentration is reduced.

Distortion Prediction of Welded Thin Plate Lap Joints by Finite Element Analysis and Experiment

2019 ◽  
Vol 796 ◽  
pp. 175-182
Author(s):  
Mohamad Nizam Ayof ◽  
Ruzaini Mohd Nawi ◽  
Nur Izan Syahriah Hussein ◽  
Nor Zulaikha Zainol
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Gas Metal Arc Welding ◽  
Three Dimensional ◽  
Welding Process ◽  
Element Model ◽  
Lap Joints ◽  
Lap Joint ◽  
Element Analysis ◽  
Metal Arc Welding

Welding process is an efficient joining process of metals that is achieved by gas metal arc welding (GMAW) process. Localized heating during welding process can result in distortion of the welded plate. The estimation of magnitude and distribution of distortion are important to maintain the quality of products. Finite element method is implemented to investigate the distortions behavior of thin steel plate, cold rolled (SPCC) material in lap joint using GMAW process. A three-dimensional, two-step thermomechanical finite element model study was applied to analyze and evaluate distortion behavior in lap joint. The result of distortion from finite element analysis (FEA) was compared to experimental data to validate the accuracy of the method.

Nonlinear Finite Element Analysis of the Bearing Capacity of a New Type of Column under Axial Load

2011 ◽  
Vol 255-260 ◽  
pp. 45-48 ◽  
Author(s):  
Ya Feng Xu ◽  
Xin Zhao ◽  
Yi Fu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Bearing Capacity ◽  
Axial Load ◽  
Load Capacity ◽  
Element Model ◽  
Steel Tube ◽  
Element Analysis ◽  
Composite Columns ◽  
Steel Ratio

Based on experimental research, the bearing performance of the new column (steel tube-reinforced concrete composite columns combination strengthened with angle steel and CFRP) has been studied in detail by finite element method. A finite element model is established based on a series of assumption. The load-displacement curves are obtained. The influence of steel ratio and thickness of CFRP layers to the bearing capacity is analyzed too. The result shows that both the steel ratio and the thickness of CFRP layers have great contribution to the axial load capacity. The finite element analysis results and theoretical analysis which are in good agreement show that simulation results are generally right.

Nonlinear Finite Element Analysis for Compressive Capacity of Interior Constrained Square Concrete-Filled Steel Tube Column

2012 ◽  
Vol 446-449 ◽  
pp. 688-694 ◽  
Author(s):  
Qi Shi Zhou ◽  
Yin Xu ◽  
Zhi Wu Yu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Steel Tube ◽  
Nonlinear Finite Element ◽  
Element Analysis ◽  
Concrete Filled Steel Tube ◽  
Short Column ◽  
Finite Element Software ◽  
Material Constitutive Relation

Nonlinear finite element model is established for the square interior constrained concrete filled steel tube column based on the research of the element type and material constitutive relation with finite element software ANSYS to find out the influence of the thickness of the steel tube, location of studs and geometry of the stirrups on the compression capacity of the short column, The results show that the compression capacity of the short column has something to do with the thickness of the steel tube and the studs, but the stirrups can eventually enhance a lot for the compression capacity as the validity is confirmed for the coherence of the results stepped from the finite element model and in test.

Finite Element Analysis of RPC-Filled Steel Tube Stub Columns

2011 ◽  
Vol 189-193 ◽  
pp. 1906-1909 ◽  
Author(s):  
Hua Luo ◽  
Zhi Gang Yan ◽  
Ming Zhe An
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Strength ◽  
Element Model ◽  
Steel Tube ◽  
Nonlinear Material ◽  
Steel Tubes ◽  
Element Analysis ◽  
Reactive Powder ◽  
Stub Columns

Reactive Powder Concrete (RPC) is a kind of cement-based composite which has ultra-high strength, high ductility and durability. RPC has great fragility, bad ductility and bursting fragility destruction subjected to high or complicated stress. The fragility performance of RPC will be improved when RPC is cast in steel tubes. The behavior of axially loaded RPC-filled steel tube circular stub columns is presented in this discussion according to the experiment and finite element analysis. An accurate finite element model was developed to carry out the analysis. Accurate nonlinear material models for confined concrete and steel tubes were used. The results obtained from the finite element analysis were verified against experimental results.

Friction Stir Butt Welding of Commercially Pure Copper Plates

2014 ◽  
Author(s):  
Gihad Karrar ◽  
A. N. Shuaib ◽  
F. A. Al-Badour ◽  
N. Merah ◽  
A. K. Mahgoub
Keyword(s):  
Finite Element ◽  
Pure Copper ◽  
Welding Process ◽  
Element Model ◽  
Butt Joint ◽  
Fe Model ◽  
Weld Quality ◽  
Element Analysis ◽  
Butt Welding ◽  
Friction Stir

This paper presents the results of studying friction stir butt welding of commercial pure copper plates using both experimental and finite element analysis methods. The experimental work consisted of making a butt joint to 4 mm copper plates using friction stir welding process at constant rotational speed of the pin tool to evaluate the effect of welding speed on weld quality. Weld quality was evaluated by the joints tensile strength, micro hardness, as well as evolution of the developed microstructure across the welding zone. A coupled Eulerian Lagrangian (CEL) finite element (FE) model had been developed to simulate the friction stir butt welding process, and predict the temperature distributions across the weld, as well as developed welding stresses. Axial load and temperature measurements results from the experiments have been used to validate the finite element model.

Finite Element Analysis on Residual Stress of Laser Brazing Diamond Wheel

2013 ◽  
Vol 712-715 ◽  
pp. 739-742 ◽  
Author(s):  
Zhi Bo Yang ◽  
Pei Fei Luo
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Element Model ◽  
Processing Parameters ◽  
Diamond Wheel ◽  
Laser Brazing ◽  
Element Analysis ◽  
The Matrix ◽  
Simulation And Experiment ◽  
Field Element

The purpose of this paper is to simulate the residual field of laser brazing by FEM of ANSYS. The 2-D coupled field element is elected to create finite element model. The brazing experiments have been done by means of 45steel which is the matrix and Ni-Cr solder and the residual stress of the diamond wheel has been measured by Raman method. The results of measure show that the maximum stress value is less strength of diamond. The residual stress distribution is basically identical between the results of simulation and experiment. According to this paper, it is possible to decrease the costs of study by selecting reasonable processing parameters on laser brazing.

scholarly journals Finite element analysis of spot laser of steel welding temperature history

2009 ◽  
Vol 13 (4) ◽  
pp. 143-150 ◽  
Author(s):  
Khalid Shibib ◽  
Mohammed Minshid ◽  
Mayada Tahir
Keyword(s):  
Finite Element ◽  
Welding Process ◽  
Element Model ◽  
Temperature History ◽  
Beam Power ◽  
Work Piece ◽  
Welding Zone ◽  
Element Analysis ◽  
Steel Cylinder ◽  
Welding Temperature

Laser welding process reduces the heat input to the work-piece which is the main goal in aerospace and electronics industries. A finite element model for axi-symmetric transient heat conduction has been used to predict temperature distribution through a steel cylinder subjected to CW laser beam of rectangular beam profile. Many numerical improvements had been used to reduce time of calculation and size of the program so as to achieve the task with minimum time required. An experimental determined absorptivity has been used to determine heat induced when laser interact with material. The heat affected zone and welding zone have been estimated to determine the effect of welding on material. The ratio of depth to width of the welding zone can be changed by proper selection of beam power to meet the specific production requirement. The temperature history obtained numerically has been compared with experimental data indicating good agreement.

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