Effect of Groove Designs on Residual Stress and Transverse Shrinkage in GMAW and PGMAW of A333 Seamless Steel Pipes

The effectiveness of weld joints primarily depends on the fusion of base metal, minimum heat-affected zone (HAZ) and lesser residual stresses. The severity of thermomechanical effects e.g. weld shrinkages and residual stresses is significantly minimized by narrow gap welding technique over the traditional welding. This work describes the welding of A333 Grade 3 steel pipes by the application of GMAW and PGMAW techniques. The analysis is made to capture the effects of groove designs on residual stress and transverse shrinkage. The process parameters used for the analysis are voltage, current and welding speed. In this work, narrow groove design using PGMAW process is capable of reducing the number of passes and area of weld deposit by 35–40% by volume. In PGMAW, decrement in residual stresses is observed with a narrow groove compared to conventional V groove technique. The results are validated by metallurgical and mechanical investigation of welded joints. This work will help other researchers to understand the effect of narrow gap welding using an optimum number of passes for thick pipes.

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Numerical investigation on residual stress distribution and evolution during multipass narrow gap welding of thick-walled stainless steel pipes

Fusion Engineering and Design ◽

10.1016/j.fusengdes.2011.01.116 ◽

2011 ◽

Vol 86 (4-5) ◽

pp. 288-295 ◽

Cited By ~ 57

Author(s):

C. Liu ◽

J.X. Zhang ◽

C.B. Xue

Keyword(s):

Residual Stress ◽

Stainless Steel ◽

Stress Distribution ◽

Numerical Investigation ◽

Residual Stress Distribution ◽

Narrow Gap ◽

Narrow Gap Welding ◽

Steel Pipes

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Modelling of residual stresses in a narrow-gap welding of ultra-thick curved steel mockup

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2018.02.024 ◽

2018 ◽

Vol 256 ◽

pp. 239-246 ◽

Cited By ~ 5

Author(s):

Chuan Liu ◽

Jiawei Yang ◽

Yifeng Shi ◽

Qiang Fu ◽

Yong Zhao

Keyword(s):

Residual Stresses ◽

Narrow Gap ◽

Narrow Gap Welding ◽

Curved Steel

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Effects of Deep Rolling on Surface Residual Stress and Microhardness of JIS SS400 MIG Welding

Materials Science Forum ◽

10.4028/www.scientific.net/msf.939.31 ◽

2018 ◽

Vol 939 ◽

pp. 31-37

Author(s):

Adirek Baisukhan ◽

Wasawat Nakkiew

Keyword(s):

Residual Stress ◽

Residual Stresses ◽

Welded Joint ◽

Rolling Process ◽

Rolling Speed ◽

Mig Welding ◽

Deep Rolling ◽

Surface Microhardness ◽

Rolling Pressure ◽

Number Of Passes

Metal Inert Gas (MIG) welding process is a common welding process for carbon steels. During the cooling after welding, non-uniform cooling cause tensile residual stress on the surface of welded joint and, in most cases, in Heat Affected Zone (HAZ) also. The tensile residual stress is undesirable because it affects the strength and shorten the workpiece fatigue life. In order to convert the tensile residual stresses to desirable compressive residual stresses, the mechanical surface treatment like deep rolling process was used in this research. The surface residual stresses were measured by XRD machine with the sin2ψ method. For statistical analysis of significant factors used in deep rolling process, there are three factors each factor has two levels: rolling pressure, rolling speed and number of passes. Taguchi experimental design was used in conjunction with a deep rolling process to determine factors affected the surface residual stresses and surface microhardness. The results of the research showed that the most significant factors that affect the surface residual stress and surface microhardness were the number of passes, followed by the rolling pressure and the rolling speed, respectively. The maximum compressive residual stress measured at the welded joint was -521.5 MPa. The highest measured surface microhardness was 266.2 HV at the welded joint. The appropriated factors of deep rolling process for JIS SS400 MIG welding were rolling pressure 270 MPa, rolling speed 1,500 mm/min and number of passes 3 times.

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A Time Saving Method to Compute Multi-Pass Weld Residual Stresses

Volume 6B: Materials and Fabrication ◽

10.1115/pvp2013-97239 ◽

2013 ◽

Cited By ~ 2

Author(s):

Lionel Depradeux ◽

Frédérique Rossillon

Keyword(s):

Residual Stress ◽

Stress Field ◽

Residual Stresses ◽

Welding Process ◽

Geometrical Parameters ◽

Residual Stress Field ◽

Time Saving ◽

3D Geometry ◽

Girth Welds ◽

Number Of Passes

In order to obtain the residual stress field resulting from the welding process, numerical simulations of multi-pass welding have demonstrated their efficiency and have become an interesting alternative to practical measurements. However, in the context of engineering studies, it remains a difficult task to compute residual stresses for a very high number of passes with reasonable computation times. In this paper, a time-saving method is proposed to simulate the welding process, ensuring an accurate reproduction of the residual stress field with drastically reduced computation times. The method consists in including in the simulation only the last deposited pass, or a reduced number of appropriately selected passes. For a given material and a given heat input, the choice of remaining passes depends on the geometrical parameters. The method is applied to various geometries of austenitic pipes girth welds, which have been widely studied in the literature and standards. The results, confronted to multipass simulations including all the passes, and to literature results, are very satisfactory. Quasi-identical residual stress fields are computed in both cases with computation times divided by a factor comprised between 7 up to 12. Further computations are in progress on other configurations than girth-weld pipes, and more complex 3D geometry like J weld of bottom head nozzles.

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Temperature distribution and residual stresses during multipass narrow gap welding of thick plates

Materials Science and Technology ◽

10.1179/174328406x83897 ◽

2006 ◽

Vol 22 (2) ◽

pp. 232-236 ◽

Cited By ~ 36

Author(s):

J. J. Xu ◽

Z. Q. Zhu ◽

L. G. Chen ◽

C. Z. Ni

Keyword(s):

Temperature Distribution ◽

Residual Stresses ◽

Narrow Gap ◽

Narrow Gap Welding ◽

Thick Plates

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ANALYSIS OF RESIDUAL STRESS FOR NARROW GAP WELDING USING FINITE ELEMENT METHOD

International Journal of Modern Physics B ◽

10.1142/s0217979210065659 ◽

2010 ◽

Vol 24 (15n16) ◽

pp. 2797-2802 ◽

Cited By ~ 1

Author(s):

CHOON YEOL LEE ◽

JAE KEUN HWANG ◽

JOON WOO BAE

Keyword(s):

Finite Element Method ◽

Residual Stress ◽

Finite Element ◽

Nuclear Power ◽

Power Plants ◽

Large Diameter ◽

Narrow Gap ◽

Narrow Gap Welding ◽

Welding Processes ◽

Element Method

Reactor coolant loop (RCL) pipes circulating the heat generated in a nuclear power plant consist of so large diameter pipes that the installation of these pipes is one of the major construction processes. Conventionally, a shield metal arc welding (SMAW) process has been mainly used in RCL piping installations, which sometimes caused severe deformations, dislocation of main equipments and various other complications due to excessive heat input in welding processes. Hence, automation of the work of welding is required and narrow-gap welding (NGW) process is being reviewed for new nuclear power plants as an alternative method of welding. In this study, transient heat transfer and thermo-elastic-plastic analyses have been performed for the residual stress distribution on the narrow gap weldment of RCL by finite element method under various conditions including surface heat flux and temperature dependent thermo-physical properties.

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Residual Stress Simulation in Multi-Pass Weld of Stainless Steel Pipes

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.578.82 ◽

2012 ◽

Vol 578 ◽

pp. 82-86 ◽

Cited By ~ 1

Author(s):

Long Shi Gao

Keyword(s):

Residual Stress ◽

Stainless Steel ◽

Residual Stresses ◽

Mechanical Analysis ◽

304 Stainless Steel ◽

The Finite Element Method ◽

Steel Pipes ◽

Integrity Assessment ◽

Temperature Distributions ◽

Stress Simulation

Multi-pass welds are used in pipes with stainless steel. The complicated temperature field and residual stresses in these welded structures are very important. The finite element method is used to simulate residual stress in multi-pass butt-welds in this paper. Element birth technique is implemented to model multi-pass welded 304 Stainless Steel Pipes. One-way coupled Thermo-mechanical analysis is adopted to calculate the residual stresses, that the structural analysis takes the temperature distributions as thermal input. The results provide reference for the structure integrity assessment of welded pipes.

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Residual Stress Generation and Relaxation in Butt-Welded Pipes

Journal of Pressure Vessel Technology ◽

10.1115/1.3264202 ◽

1982 ◽

Vol 104 (3) ◽

pp. 188-192 ◽

Cited By ~ 3

Author(s):

S. Nair ◽

E. Pang ◽

R. C. Dix

Keyword(s):

Heat Treatment ◽

Residual Stress ◽

Stainless Steel ◽

Residual Stresses ◽

Numerical Scheme ◽

Stress Generation ◽

304 Stainless Steel ◽

Thermally Induced ◽

Steel Pipes

A numerical scheme for the determination of thermally induced local residual stresses and their relaxation behavior during heat treatment in the case of butt-welded pipes is described. The procedure is illustrated by considering 304 stainless steel and SAE 1020 steel pipes. The results are compared with available experimental and numerical results.

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