Computational methods and experimental validation of welding distortion models

2007 ◽  
Vol 221 (4) ◽  
pp. 235-249 ◽  
Author(s):  
D Camilleri ◽  
P Mollicone ◽  
T G F Gray
Keyword(s):  
Experimental Study ◽  
Residual Stresses ◽  
Thin Plate ◽  
Computational Methods ◽  
Experimental Validation ◽  
Experimental Tests ◽  
Welding Distortion ◽  
Computationally Efficient ◽  
Welded Structures ◽  
Out Of Plane

Multiply-stiffened, thin plate, welded fabrications are used in a wide variety of transport fields, however the resulting out-of-plane distortion associated with welding exacts a severe design penalty. Depending on the information required, the size of the structure under investigation and the computer power at hand, three computational strategies may be considered to predict welding distortion. If prediction of the localized residual stresses from welding is of major importance, then a full transient, uncoupled thermo-elastoplastic analysis is preferred. This method is not readily applicable to predict welding distortions in industrial-scale welded structures. More computationally efficient models are required and two other models are suggested in the current study. A series of experimental tests of a realistic nature were performed to validate the proposed computational strategies. Computational and experimental study of butt and fillet welding of small and industrial size fabrications is considered.

Benchmark Investigation of Welding-Induced Buckling and Its Critical Condition During Thin Plate Butt Welding

2019 ◽  
Vol 141 (7) ◽  
Author(s):  
Jiangchao Wang ◽  
Bin Yi
Keyword(s):  
Finite Element ◽  
Thin Plate ◽  
Measurement Data ◽  
Characteristic Parameter ◽  
Welding Distortion ◽  
Butt Welding ◽  
Buckling Behavior ◽  
Out Of Plane ◽  
Inherent Deformation ◽  
Good Agreement

Welding-induced buckling is a special type of welding distortion occurring during thin plate butt welding and was investigated using both experimental and computational approaches for this benchmark investigation. In addition, the characteristic parameter and its magnitude for the occurrence of welding-induced buckling were also presented. Fundamental theories of the inherent deformation, finite strains, and eigenvalues of the structure stiffness matrix were considered to investigate welding-induced buckling. A series of experiments on thin plate butt welding with different heat inputs were conducted, and buckling behavior was observed from the deformed shape and the distribution of out-of-plane welding distortion. Transient nonlinear thermal elastic–plastic finite element (TEP FE) and elastic finite element (FE) analyses were conducted to predict welding-induced buckling, and the results were in good agreement with the measurement data. Criteria for the occurrence of welding-induced buckling were proposed and discussed. Inherent deformation was considered as a characteristic parameter of buckling behavior during welding, and its critical magnitude was calculated using a loading incremental method and eigenvalue analysis with good agreement.

Design Support Tool for Prediction of Welding Distortion in Multiply Stiffened Plate Structures: Experimental and Computational Investigation

2005 ◽  
Vol 21 (04) ◽  
pp. 219-234
Author(s):  
Duncan Camilleri ◽  
Tugrul Comlekci ◽  
Thomas G. F. Gray
Keyword(s):  
Large Scale ◽  
Computational Models ◽  
Plane Deformation ◽  
Computational Prediction ◽  
Welding Distortion ◽  
Plate Structures ◽  
Welded Structures ◽  
Welding Sequence ◽  
Out Of Plane ◽  
Welding Processes

Many industries, such as shipbuilding, concerned with the fabrication of fusionwelded plate structures, face increasing challenges to produce lightweight structures. This design requirement is commonly met by using thin-plate, multiply stiffened, welded structures, but severe difficulties and high rectification costs are frequently incurred, related to the evolution of out-of-plane deformations. The overall scope of this study is to improve the applicability of computational prediction of distortion by providing simple and adaptable methodologies, which can be readily validated through experience of application in the industrial context. These methods are designed to be computationally economic and robust, and they are also generic with respect to material properties, welding processes, and thickness. The aim is to provide design engineers with the tools to explore alternative structural and process parameters and hence to find out if the outcomes will be acceptable, prior to embarking on manufacturing operations typical of large-scale welded structures. The validity of the simulations was investigated via full-scale tests where several filletwelded 100 mm × 6 mmstiffeners were attached to 4 m × 1.5 m × 5 mmthick plates, according to different sequences. The computational models were used to optimize the welding scheme with respect to minimum out-of-plane deformation and welding sequence.

Numerical Modelling of Residual Stress and Distortion in Welded Thin Steel Plates

2008 ◽  
Author(s):  
M. Tsunori ◽  
C. M. Davies ◽  
D. Dye ◽  
K. M. Nikbin
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welding Process ◽  
Steel Plates ◽  
Thin Plates ◽  
Welding Distortion ◽  
Butt Welding ◽  
Thin Steel ◽  
Out Of Plane ◽  
Plate Size

Current trends in ship design are to reduce panel thickness in order to minimise the vessels weight and hence maximise speed. These panels are manufactured through butt welding thin steel plates with the addition of fillet welded stiffeners. Excessive distortions are exhibited in these thin plates due to the welding process, resulting in major rectification or re-manufacturing costs. The aim of this study is to develop a tool to predict welding residual stresses and distortions in order to understand their governing factors, and thus enabling the optimum fabrication processes to be realized to minimise welding distortion. Finite element simulations are performed of the butt and fillet welding process in 4 mm thick plates of ferritic DH-36 steel and the residual stresses and distortions are predicted. Thermal and residual stress profiles are verified against experimental measurements. The effects of plate and stiffener dimensions are examined numerically. In addition, a sensitivity analysis has been carried out to quantify the effects of restraint on a small butt welded plate. It is concluded that final distortion may be severely reduced, in the plate size considered, if only an out-of-plane constraint is imposed on the plate’s surfaces. Further welding experiments are required to validate these findings.

scholarly journals Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 141 ◽  
Author(s):  
Hui Huang ◽  
Xianqing Yin ◽  
Zhili Feng ◽  
Ninshu Ma
Keyword(s):  
Finite Element ◽  
Thin Plate ◽  
Heat Input ◽  
Plane Deformation ◽  
Welding Process ◽  
Numerical Results ◽  
Tig Welding ◽  
Image Correlation ◽  
Welding Distortion ◽  
Out Of Plane

Transient distortion of thin plate in the welding process usually has a complicated mode and large magnitude. Quantitative measurement and prediction of full-field distortion are challenging and rarely reported up to now. In this study, the out-of-plane distortion of a thin plate during the Tungsten Inert Gas (TIG) welding process was measured using the digital image correlation (DIC) method. A simulation model based on thermal elastic–plastic finite element method (FEM) and DIC measured geometric imperfection were developed for accurate prediction of the transient welding distortion. The numerical results and experimental data agreed very well in both out-of-plane deformation modes and magnitudes of the plate at different stages of welding. The maximum out-of-plane distortion was larger than 4 mm during welding which can cause instability of arc length and heat input. The distance change between welding torch and plate surface was investigated under different initial deflections of the plate before welding. The plate with flat geometry shows the minimum transient and final gap change. In addition, the relationship between heat input and welding distortion was clarified through a series of numerical analyses. Optimization of welding heat input can be performed based on numerical results to avoid excessive welding distortion.

Recent Developments in Experimental and Numerical Assessments of Welding-Induced Residual Stresses

2018 ◽  
Author(s):  
Bai-Qiao Chen ◽  
Marzieh Hashemzadeh ◽  
Yordan Garbatov ◽  
C. Guedes Soares
Keyword(s):  
Residual Stresses ◽  
Large Scale ◽  
Three Dimensional ◽  
Experimental Tests ◽  
Welded Structures ◽  
Simulation Techniques ◽  
Numerical Assessment ◽  
Welding Sequence ◽  
Recent Developments ◽  
Inherent Deformation

The objective of this work is to present and review the recent developments in the experimental and numerical assessment and simulation techniques on the welding induced distortions and residual stresses. The temperature distribution, welding induced distortion and residual stresses in thin walled welded structures, originating from different experimental tests are reviewed and discussed. Different mathematical models and their numerical applications in representing the heat source are analysed and their advantages and drawbacks are discussed. Thermal stress analyses employing the three-dimensional nonlinear thermo-elasto-plastic approaches and finite element simulations with inherent deformation applicable to large-scale and complex welded structures are also revised and discussed. Discussions on the material properties of the base metal, heat affected zone (HAZ) and weld metal, the effect of the welding sequence, and the pattern of residual stress distribution presented are given a special attention.

Recent M.I.T. Research on Residual Stresses and Distortion in Welded Structures

1993 ◽  
Vol 9 (03) ◽  
pp. 137-145
Author(s):  
Koichi Masubuchi
Keyword(s):  
Residual Stresses ◽  
Intelligent System ◽  
High Strength ◽  
Steel Plates ◽  
Ocean Engineering ◽  
Welded Structures ◽  
Butt Welding ◽  
Knowledge Based ◽  
Out Of Plane ◽  
Longitudinal Bending

This paper presents a summary of recent efforts by the Welding Research Group at the Department of Ocean Engineering, M.l.T. The major thrust of the efforts has been to develop technologies of reducing residual stresses and distortion through in-process control. Part 1 discusses reduction of longitudinal bending distortion of built-up beams, reduction of radial distortion and residual stresses in girth- welded pipes, reduction of forces acting on tack welds during butt welding, and reduction of residual stresses and distortion in high-strength steel weldments. Part 2 presents a brief summary of other research studies, including the forming of steel plates by line heating with a high-power laser beam, an intelligent system for flame straightening of panel structures, and the development of a knowledge- based system for minimizing out-of-plane distortion of welded structures.

Numerical simulation and experimental validation of angular distortion and residual stresses in a T-joint

2015 ◽  
Vol 57 (7-8) ◽  
pp. 628-634
Author(s):  
Jing Chen ◽  
Liying Wang ◽  
Zhendong Shi ◽  
Zhen Dai ◽  
Meiqing Guo
Keyword(s):  
Numerical Simulation ◽  
Residual Stresses ◽  
Experimental Validation ◽  
Angular Distortion
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