Influences of Welding Sequence on Residual Stress of Plate Butt Welding

2010 ◽  
Vol 26-28 ◽  
pp. 568-572
Author(s):  
Peng Ji ◽  
Qing Hua Dai ◽  
Chen Bo Yin ◽  
Di Sheng Yi ◽  
Bin Wang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Butt Welding ◽  
Welding Sequence ◽  
Longitudinal Residual Stress ◽  
Welding Sequences ◽  
Large Side

For the plate butt welding of the same materials with different geometry structures, the numerical simulation was adopted to analyze the influences of welding sequence on transverse and longitudinal residual stress in the process of multi-layer and multi-pass welding. The results show that when welding from the small geometric side to the large side, the peak values of transverse and longitudinal residual stress are min along the bottom or top axis of the weld. And the welding sequences of the foremost welds have little effects on transverse and longitudinal residual stress along the bottom or top axis of the weld.

Numerical Simulation of Welding for Box Beam Structure on Bogie of High Speed Train

2011 ◽  
Vol 399-401 ◽  
pp. 1816-1819
Author(s):  
Huan Jun Liu ◽  
Jian Xin Liu ◽  
Hui Chen ◽  
Hua Ji ◽  
Zhi Yi Zhang
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
High Speed ◽  
Weathering Steel ◽  
Beam Structure ◽  
Element Analysis ◽  
Box Beam ◽  
Welding Sequence ◽  
Side Beam ◽  
Welding Sequences

In this paper a typical box beam structure on certain high speed power car was taken as study object, Based on the finite element analysis software SYSWELD, established the material parameters database for SMA490BW weathering steel, and performed the numerical simulation for the welding of typical box beam structure of side beam of high speed bogie, comparison between the simulation results and that of experiment test verified the existing welding procedures. For the purpose of studying the influence of welding sequence on the residual stress and providing theoretical support for actual production, the residual stress under different welding sequences was investigated then.

Numerical Simulation of the Effects of Preheating on Electron Beam Additive Manufactured Ti-6Al-4V Build Plate

2016 ◽  
Vol 879 ◽  
pp. 274-278 ◽  
Author(s):  
Jun Cao ◽  
Philip Nash
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Finite Element ◽  
Electron Beam ◽  
Cross Section ◽  
Element Model ◽  
Normal Direction ◽  
Thermal Residual Stresses ◽  
Longitudinal Residual Stress ◽  
Middle Cross Section

In an earlier study, a 3-D thermomechanical coupled finite element model was built and experimentally validated to investigate the evolution of the thermal residual stresses and distortions in electron beam additive manufactured Ti-6Al-4V build plates. In this study, an investigation using this robust and accurate model was focused on an efficient preheating method, in which the electron beam quickly scanned across the substrate to preheat the build plate prior to the deposition. Various preheat times, beam powers, scan rates, scanning paths and cooling times (between the end of current preheat scan/deposition layer and the beginning of the next preheat scan/deposition layer) were examined, and the maximum distortion along the centerline of the substrate and the maximum longitudinal residual stress along the normal direction on the middle cross-section of the build plate were quantitatively compared. The results show that increasing preheat times and beam powers could effectively reduce both distortion and residual stress for multiple layers/passes components.

Numerical Simulation for Residual Stress and Deformation of Surface Welding on Membrane Water-Wall

2014 ◽  
Vol 490-491 ◽  
pp. 594-599
Author(s):  
Fan Ling Meng ◽  
Ai Guo Liu
Keyword(s):  
Residual Stress ◽  
Great Influence ◽  
Residual Deformation ◽  
Welding Residual Stress ◽  
Finite Element Software ◽  
Welding Sequence ◽  
Surface Welding ◽  
Stress And Deformation ◽  
Welding Sequences ◽  
Residual Stress And Deformation

Automatic MIG was adopted to weld Inconel 625 alloy on 20 G Membrane Waterwall, which can improve the capacities of high temperature corrosion resistance and wear resistance. To study the influence of Membrane Waterwall surface welding sequences on residual stress and residual deformation, this paper utilized finite element software ABAQUS and segmented moving heat source model to simulate the sequence welding, balanced welding from the middle to sides, balanced welding from sides to the middle, balanced skip welding from middle to sides and balanced skip welding from sides to the middle and studied their residual stresses and deformations. The simulation results indicated that there was a great influence of welding sequences on the residual stress and deformation. The optimal welding sequence was balanced skip welding from middle to sides and balanced skip welding from sides to the middle, which could change the stress distribution, decrease the welding residual stress by 17%, realize the even deformation of the whole welding section and decrease the bending deformation by 50%.

Numerical Study of Welding Sequence on the Residual Stress Field in a Thick-Walled Tee Joint

2011 ◽  
Vol 219-220 ◽  
pp. 1211-1214
Author(s):  
Wei Jiang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Numerical Study ◽  
Three Dimensional ◽  
Element Model ◽  
Residual Stress Field ◽  
Factors Affecting ◽  
Welding Sequence ◽  
Welding Sequences ◽  
Three Dimensional Finite Element

Finite element simulation is an efficient method for studying factors affecting weld-induced residual stress distributions. In this paper, a validated three-dimensional finite element model consisting of sequentially coupled thermal and structural analyses was developed. Three possible symmetrical welding sequences, i.e. one-welder, two-welder and four-welder sequence, which were perceived to generate the least distortion in actual welding circumstances, were proposed and their influences on the residual stress fields in a thick-walled tee joint were investigated. Appropriate conclusions and recommendations regarding welding sequences are presented.

scholarly journals The Effect of Welding-Pass Grouping on the Prediction Accuracy of Residual Stress in Multipass Butt Welding

2017 ◽  
Vol 2017 ◽  
pp. 1-13
Author(s):  
Jeongung Park ◽  
Gyubaek An ◽  
Sunghoon Kim
Keyword(s):  
Residual Stress ◽  
Diffraction Method ◽  
Fe Analysis ◽  
Computer Memory ◽  
Butt Weld ◽  
Butt Welding ◽  
Welded Structure ◽  
Welding Sequence ◽  
Grouping Method ◽  
Neutron Diffraction Method

The residual stress analysis of a thick welded structure requires a lot of time and computer memory, which are different from those in thin welded structure analysis. This study investigated the effect of residual stress due to welding-pass grouping as a way to reduce the analysis time in multipass thick butt welding joint. For this purpose, the parametric analysis which changes the number of grouping passes was conducted in the multipass butt weld of a structure with a thickness of 25 mm and 70 mm. In addition, the residual stress by thermal elastoplastic FE analysis is compared with the results by the neutron diffraction method for verifying the reliability of the FE analysis. The welding sequence is considered in order to predict the residual stress more accurately when using welding-pass grouping method. The results of the welding-pass grouping model and half model occurred between the results of the left/right of the full model. If the total number of welding-pass grouping is less than half of that of welding pass, a large difference with real residual stress is found. Therefore, the total number of the welding-pass grouping should not be reduced to more than half.

Numerical Simulation of Welding Sequence Effect on Temperature Distribution, Residual Stresses and Distortions of T-Joint Fillet Welds

2011 ◽  
Vol 264-265 ◽  
pp. 254-259 ◽  
Author(s):  
N. Syahroni ◽  
M.I.P. Hidayat
Keyword(s):  
Numerical Simulation ◽  
Temperature Distribution ◽  
Residual Stresses ◽  
Angular Distortion ◽  
Element Simulation ◽  
Welding Sequence ◽  
And Performance ◽  
Welding Sequences ◽  
Two Sides ◽  
Contrary Direction

Welding sequence is one important factor which affects the residual stresses and distortions produced during welding, thus determines the welding quality and performance. In this paper, 3D numerical simulation of temperature distribution, residual stresses and distortions of the T-joint fillet weld with respect to the variation of welding sequence is presented. The finite element simulation involved thermo-mechanical analyses. Four welding sequences (WS) considered are one direction welding (WS-1), contrary direction welding (WS-2), welding from centre of one side (WS-3) and welding from centres of two sides (WS-4). The simulation results revealed that peak temperature achieved in the welding was greatly affected by the welding sequence and residual stress and angular distortion produced cannot both hold in minimum for a WS. The smallest residual stresses and the smallest angular distortions are related respectively to WS-2 and WS-4. The distributions of temperature, longitudinal and transverse residual stresses as well as angular distortions were also presented.

Influence of the Welding Sequence on Residual Stresses in Laser Welded T-Joints of an Airframe Aluminium Alloy

2008 ◽  
Vol 571-572 ◽  
pp. 375-380 ◽  
Author(s):  
Winulf Machold ◽  
Peter Staron ◽  
Funda S. Bayraktar ◽  
Stefan Riekehr ◽  
Mustafa Koçak ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welding Process ◽  
Base Plate ◽  
Stress Fields ◽  
Stress Concentrations ◽  
T Joints ◽  
Element Simulation ◽  
Welding Sequence ◽  
Welding Sequences

The effect of different welding sequences between a 4.5 mm thick AA 6156 T6 base plate and a 2 mm thick AA 6013 T6 clip – resembling a skin-clip joint of an airframe – using a 3.3 kW Nd:YAG laser is investigated. Under cyclic loading the breakdown of such T-joints happens at one end of the clip, which is due to local residual stress concentrations. Recent measurements indicated that tensile stresses could be lower at the run-in than at the run-out locations. For a deeper investigation of this effect sheets with different welding sequences were produced. One welding sequence was made with two starting points in the centre, and a second with starting points at the clip ends. Temperature measurements were made using thermocouples to verify the heat conditions for a finite element simulation of the welding process, which is used for predictions of the residual stress distribution. Actual values of the residual stress fields were determined by neutron diffraction. The influences of the welding sequence on the measured temperatures and the residual stresses are discussed.

Numerical Simulation of TIG Welding Distortions: Distortions of a Mock-Up Representative of ITER Vacuum Vessel

2011 ◽  
Author(s):  
Denis Pont ◽  
Mathieu Tisset ◽  
Fre´de´ric Boitout ◽  
Philippe Gilles
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Numerical Simulations ◽  
Nuclear Industry ◽  
Local Fields ◽  
Design Stage ◽  
Strong Impact ◽  
Vacuum Vessel ◽  
Welding Simulation ◽  
Welding Sequence

Welding problems encountered in the nuclear industry have been mainly addressed by weldability tests and the analysis, development of new techniques or improvements through lesson learning. Since a decade, AREVA is developing a complementary approach based on numerical simulation. Residual stresses present in reactors do not constitute a major problem at the design stage; even though they may have a strong impact on some types of damage. Numerical welding simulation in the nuclear industry has focused mainly on residual stress prediction, which constitutes an issue for engineering. PWR components are usually massive; nevertheless distortion may also be a source of concern in component design: some structures are slender in spite of their thickness; narrow gap welding requires a close control of the groove width. AREVA, also working on a fast breeder project, the distortion problem gains in importance. In this prospect, AREVA, world energy expert, paid special attention on the numerical simulation of Gas Tungsten Arc Welding (GTAW) of a mock-up relative to the International Thermonuclear Experimental Reactor (ITER) Vacuum Vessel (VV). One of the challenges of manufacturing the ITER vacuum vessel is the low value of acceptance level of distortion (∼ 10 mm) compared to the global dimensions of the structure (∼ 10 m). Welding simulations of a representative mock-up of VV pattern of the made of austenitic steel plates (316L(N) ITER GRADE) are carried out. The aim of the numerical simulations is to check the quality of the distortion prediction. Multi pass welding simulation reproduces the deposit of each bead by thermo-metallurgical and mechanical calculations. Distortions induced by each weld are computed using a simplified approach (local global method). This method aims at modeling long and numerous welding operations with an acceptable calculation time. Moreover, this method is improved in order to respect welding sequence with partial filling of grooves. After welding sequences, distortions are measured at some representative points of the mock-up. The paper presents the methodology of the numerical simulations and the relevant results: • Residual stress and strain fields in and near the welds (local fields), • Distortion prediction for the global structure. The comparison with experimental distortions shows that the trends of the experimental deformed shape are well represented by the simulations. Moreover, displacement magnitudes are in good agreement with measurements.

scholarly journals Influence of Interlayer Temperature and Welding Sequence on the Temperature Distribution and Welding Residual Stress of the Saddle-Shaped Joint of Weldolet-Header Butt Welding

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 5980
Author(s):  
Chunliang Mai ◽  
Xue Hu ◽  
Lixin Zhang ◽  
Bao Song ◽  
Xiongfei Zheng
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Stress Distribution ◽  
High Stress ◽  
Welding Process ◽  
Residual Stress Distribution ◽  
Welding Residual Stress ◽  
Two Stage ◽  
Welding Sequence ◽  
Simulation Results

In this paper, based on Simufact Welding finite element analysis software, a numerical simulation of the temperature and residual stress distribution of the weldolet-header multi-layer multi-pass welding process is carried out, and the simulation results are verified through experiments. The experimental results are in good agreement with the numerical simulation results, which proves the validity of the numerical simulation results. Through the results of the numerical simulation, the influence of the welding sequence and interlayer temperature on the temperature and residual stress distribution at different locations of the saddle-shaped weld was studied. The results show that the temperature and residual stress distribution on the header and weldolet are asymmetric, and the high-stress area of the saddle-shaped welded joint always appears at the saddle shoulder or saddle belly position. When the interlayer temperature is 300 °C, the peak residual stress reaches a minimum of 428.35 MPa. Adjusting the welding sequence can change the distribution trend of residual stress. There is no high-stress area on the first welding side of the two-stage welding path-2. The peak values of residual stresses for continuous welding path-1 and two-stage welding path-2 are 428.35 MPa and 434.01 MPa, respectively, which are very close to each other.

Welding Sequence Optimization of TA15 Airplane Wall Panels

2011 ◽  
Vol 704-705 ◽  
pp. 1045-1050
Author(s):  
Zhi Bo Dong ◽  
Yan Hong Wei ◽  
Wen Jian Zheng ◽  
Guang Xu Hu ◽  
Rui Ma
Keyword(s):  
Residual Stress ◽  
Service Performance ◽  
Welding Distortion ◽  
Stress Distributions ◽  
Welding Quality ◽  
Welding Sequence ◽  
Wall Panels ◽  
Welding Head ◽  
Welding Sequences ◽  
Good Agreement

TA15 airplane wall panels are used widely in aircraft manufacture, which consist of some reinforced ribs and a motherboard. Therefore, welding sequences of different reinforced ribs directly determine distortion and residual stress distributions of welding wall panels, and then affect the structure service performance. Therefore, it is important to get the optimistic sequence during manufacture processing of welding wall panels. This paper analyses and predicts regularities of distributions of residual distortion and stress under four kinds of different welding sequence namely, order welding sequence, head-tail welding, head-tail symmetry welding and center symmetry welding. Compared the distortion and residual stress of four kinds of sequences, it is obvious that the welding distortion is smaller and welding quality is better under head-tail symmetry welding sequence, and the order welding sequence is the worst. The simulated distortions are in good agreement with the experiments. So this study puts forward the best welding sequence when welding airplane wall panels, which adapt to any amounts of reinforced ribs welded with the motherboard.

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