Transversed Residual Stress Analysis on Multipassed Fillet Weld 2D-Using FEM and Experiment

2012 ◽  
Vol 576 ◽  
pp. 181-184
Author(s):  
Mohd Ridhwan Mohammed Redza ◽  
Yupiter H.P. Manurung ◽  
Robert Ngendang A. Lidam ◽  
Mohd Shahar Sulaiman ◽  
Mohammad Ridzwan Abdul Rahim ◽  
...  
Keyword(s):  
Residual Stress ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Simulation Method ◽  
Low Carbon ◽  
Robotic Welding ◽  
Element Analysis ◽  
Fillet Weld ◽  
Simulation And Experiment ◽  
Fea Simulation

In this project, the residual stress due to multipassed welding process at the fillet weld will be studied using 2D Finite Element Analysis (FEA) simulation method and experimental investigation. Due to the extensive capabilities and dedicated tools for the simulation of welding, including material deposit via element activation or deactivation and predefined or customized moving heat sources, SYSWELD 2010 was chosen as the FEA software. The material with a thickness of 9 mm was structural steel S355J2G3 for simulation and low carbon steel for the experiment. The clamping condition was selected to obtain the best relationship between simulation and experiment by using Strain Gage. The model was dedicated to multipassed welding using the robotic welding system

Fatigue Analysis of Cladded HPHT Pressure Containing Equipment

2016 ◽  
Author(s):  
Kumarswamy Karpanan ◽  
Nicholas Gatherar
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Plastic Material ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Fatigue Loading ◽  
Low Carbon ◽  
Working Pressure ◽  
Element Analysis ◽  
Test Pressure

Large, pressure-containing equipment used in subsea production, including Christmas trees (XTs), gate valves, flowloops, jumpers, and connectors, are constructed of low-carbon steel and cladded with corrosion resistant alloys such as Alloy 625. Cladding is a welding process that generates high tensile residual stresses on the cladded layer and on the heat affected zone (HAZ). High pressure high temperature (HPHT) equipment for subsea applications, designed to operate above 15 ksi internal pressure and 350°F, is also cladded. This equipment experiences severe working conditions in the field, plus cyclic loading during operations, such as riser loads, installation, intervention and, most importantly, startup and shutdown sequences. Per API 17TR8 guidelines, all HPHT equipment be hydrostatically tested to 1.5 times the equipment rated working pressure (RWP). For 20 ksi equipment, the hydrostatic test pressure is 30 ksi, which can significantly deform any highly localized stressed regions. These regions deform plastically when test pressure is applied. When the pressure is bled, these regions experience high compressive stresses due to surrounding materials that are still elastic. This paper analyzes a simplified HPHT cladded gate valve (GV) body for fatigue loading (pressure cycles only) using the ASME Sec VIII, Div-3 method. The fatigue stress amplitude is calculated using an elastic-plastic material (E-P method) finite element analysis. In this method, first, the residual stress from the cladding process is simulated, and then the hydrotest is simulated on the component. During the hydrostatic test, fatigue sensitive regions (FSRs) or highly localized stressed regions such as the valve cavity and seat pockets, deform plastically, and the initial weld tensile residual stress turns to compressive (similar to autofrettage). Later, when these components are subjected to working pressure cycles (startup and shutdown), the shear stress range remains the same but the mean stress on the FSR reduces significantly. By considering all types of residual stresses, the high cycle fatigue life can be predicted with a high degree of accuracy.

Analysis on the Residual Stresses in Functionally Gradient Fe360/Glass-Ceramic Coatings

2013 ◽  
Vol 717 ◽  
pp. 215-220
Author(s):  
Li Ming Zhou ◽  
Wei Gong ◽  
En Ze Wang
Keyword(s):  
Residual Stress ◽  
Glass Ceramic ◽  
Volume Fraction ◽  
Geometric Model ◽  
Low Carbon Steel ◽  
Ceramic Coatings ◽  
Low Carbon ◽  
Element Analysis ◽  
Functionally Gradient ◽  
Gradient Coatings

A novel functionally gradient composite was reported in this article. The composite material are composed of plain low carbon steel Fe360 as a substrate and glass-ceramics containing ZrO2 reinforcing particles as a coating. Based on a mathematical model of the residual stress, the geometric model and finite element analysis models of the Fe360/glass-ceramic gradient coatings were established. The residual stress of the gradient layers was calculated with the commercial software ANSYS 10.0. The results showed that the differences of thermal expansion coefficient and shrinkage rate in each layer resulting from the difference of the volume fraction of ZrO2 in each gradient layer could make the surface layer generate suitable compressive stress. The maximum residual stress presents itself at the interface between the substrate and the gradient coatings. The layer numbers and the thickness of graded coatings have a significant effect on the residual stress.

Distortion Analysis on Multipassed Butt Weld Using FEM and Experimental Study

2011 ◽  
Vol 311-313 ◽  
pp. 811-814
Author(s):  
Mohd Ridhwan Mohammed Redza ◽  
Yupiter H.P. Manurung ◽  
Robert Ngendang Ak. Lidam ◽  
Mohd Shahar Sulaiman ◽  
Mohammad Ridzwan Abdul Rahim ◽  
...  
Keyword(s):  
Gas Metal Arc Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Travel Speed ◽  
Source Model ◽  
Low Carbon ◽  
Robotic Welding ◽  
Butt Weld ◽  
Metal Arc Welding ◽  
Weld Distortion

This paper investigates the simulation technique for analyzing the distortion behavior induced by welding process on welded plate which was clamped on one side. This clamping method is intended to enable the investigation of the maximum distortion on the other side. FEA software SYSWELD was employed to predict multipassed butt weld distortion of low carbon steel with thicknesses of 6 mm and 9 mm. The simulation begins with the development of model geometry and meshing type followed by suitable selection of heat source model represented by the Goldak’s double ellipsoid model. Other parameters such as travel speed, heat input, clamping method etc. were determined. The model is dedicated for multipass welding techniques using Gas Metal Arc Welding (GMAW). The experimental works were conducted by using Robotic welding process.

Numerical Analysis and Testing of Tungsten Inert Gas Welded T-Joints

2017 ◽  
Vol 9 (2) ◽  
Author(s):  
A. Arun Kumar ◽  
S. Ravichandran ◽  
M. Kumaresan ◽  
P. Sathish
Keyword(s):  
Power Plants ◽  
Optimization Technique ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Tensile Load ◽  
Inert Gas ◽  
Low Carbon ◽  
Taguchi Optimization ◽  
Element Analysis ◽  
Parent Materials

Presently arc welded structures are extensively used in automobiles, constructions and power plants. As the main cause of weldment failure is design defect and overload, it is necessary to analyze the maximum stresses in the weldment. This work deals with investigation of welded T-joint by Tungsten Inert Gas (TIG) welding process with varying gap and angle between the parent materials to determine the breaking stress under tensile load in the weldment. Finite element analysis is carried out using Ansys software and results are compared with experimental analysis using Taguchi optimization method. Angle, arc force and gap between parent materials are used for the Taguchi optimization technique. The optimized fillet weld section (low carbon steel AISI1020 and copper) is arrived by restricting the weldment failure.

The Temperature Field Test and Numerical Simulation of Steel’s Friction Stir Welding Process

2013 ◽  
Vol 706-708 ◽  
pp. 370-374 ◽  
Author(s):  
Xi Jing Wang ◽  
Yong Xin Lu ◽  
Zhong Ke Zhang ◽  
Jian Li Liang ◽  
Ting Kai Guo
Keyword(s):  
Temperature Field ◽  
Friction Stir Welding ◽  
Heat Input ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Transient Temperature ◽  
Low Carbon ◽  
Element Analysis ◽  
Friction Stir ◽  
Friction Stir Welding Process

For the friction stir welding technology of the low carbon steel, according to the character of the friction stir welding process, the researchers build a simplified heat input numerical model, and use the finite element analysis software ANSYS to simulate the transient temperature field distribution and the feature points of thermal cycle curve of the 4 mm Q235A steel in the butt joint. Comparing the simulation results and the feature point temperature curve measured by the thermocouple, the researchers verify the heat input model and simulation method is correct. It provides the scientific basis to select the right experimental parameters.

scholarly journals Optimization Study of Post-Weld Heat Treatment for 12Cr1MoV Pipe Welded Joint

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 127
Author(s):  
Zichen Liu ◽  
Xiaodong Hu ◽  
Zhiwei Yang ◽  
Bin Yang ◽  
Jingkai Chen ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Stress Reduction ◽  
Simulation Method ◽  
Post Weld Heat Treatment ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Tempering Treatment ◽  
Temper Heat Treatment ◽  
Weld Heat

In order to clarify the role of different post-weld heat treatment processes in the manufacturing process, welding tests, post-weld heat treatment tests, and finite element analysis (FEA) are carried out for 12C1MoV steel pipes. The simulated temperature field and residual stress field agree well with the measured results, which indicates that the simulation method is available. The influence of post-weld heat treatment process parameters on residual stress reduction results is further analyzed. It is found that the post weld dehydrogenation treatment could not release residual stress obviously. However, the residual stress can be relieved by 65% with tempering treatment. The stress relief effect of “post weld dehydrogenation treatment + temper heat treatment” is same with that of “temper heat treatment”. The higher the temperature, the greater the residual stress reduction, when the peak temperature is at 650–750 °C, especially for the stress concentration area. The longer holding time has no obvious positive effect on the reduction of residual stress.

Measurement and Calculation of Elastic Properties in Low Carbon Steel Sheet

2005 ◽  
Vol 495-497 ◽  
pp. 1591-1596 ◽  
Author(s):  
Vladimir Luzin ◽  
S. Banovic ◽  
Thomas Gnäupel-Herold ◽  
Henry Prask ◽  
R.E. Ricker
Keyword(s):  
Carbon Steel ◽  
Elastic Property ◽  
Elastic Properties ◽  
Steel Sheet ◽  
Low Carbon Steel ◽  
Low Carbon ◽  
Forming Process ◽  
Element Analysis ◽  
Wide Range ◽  
Carbon Steel Sheet

Low carbon steel (usually in sheet form) has found a wide range of applications in industry due to its high formability. The inner and outer panels of a car body are good examples of such an implementation. While low carbon steel has been used in this application for many decades, a reliable predictive capability of the forming process and “springback” has still not been achieved. NIST has been involved in addressing this and other formability problems for several years. In this paper, texture produced by the in-plane straining and its relationship to springback is reported. Low carbon steel sheet was examined in the as-received condition and after balanced biaxial straining to 25%. This was performed using the Marciniak in-plane stretching test. Both experimental measurements and numerical calculations have been utilized to evaluate anisotropy and evolution of the elastic properties during forming. We employ several techniques for elastic property measurements (dynamic mechanical analysis, static four point bending, mechanical resonance frequency measurements), and several calculation schemes (orientation distribution function averaging, finite element analysis) which are based on texture measurements (neutron diffraction, electron back scattering diffraction). The following objectives are pursued: a) To test a range of different experimental techniques for elastic property measurements in sheet metals; b) To validate numerical calculation methods of the elastic properties by experiments; c) To evaluate elastic property changes (and texture development) during biaxial straining. On the basis of the investigation, recommendations are made for the evaluation of elastic properties in textured sheet metal.

Finite element analysis of the residual stress of automotive wheel made of long glass fiber-reinforced thermoplastic composite

2018 ◽  
Vol 233 (10) ◽  
pp. 3592-3602 ◽  
Author(s):  
Weihao Chai ◽  
Xiandong Liu ◽  
Yinchun Shan ◽  
Xiaofei Wan ◽  
Er Jiang
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Simulation Method ◽  
Residual Stress Distribution ◽  
Thermoplastic Composite ◽  
Element Analysis ◽  
Simulation Accuracy ◽  
Glass Fiber Reinforced ◽  
Long Glass Fiber ◽  
Bending Fatigue Test

To increase the simulation accuracy, a finite element analysis method for the prediction of the residual stress distribution in the injection molded wheel made of the long glass fiber-reinforced thermoplastic composite (LGFT) is studied, and a simulation method of the wheel bending fatigue test considering the residual stress distribution is investigated in this paper. First, the in-cavity residual stress is calculated using the molding simulation method. Then the residual stress relaxation process is analyzed and the final residual stress distribution is obtained. With the residual stress as the initial stress, the structural simulation of the LGFT wheel under the bending load is performed. To evaluate the influence of the residual stress on the LGFT wheel, an additional simulation without considering the residual stress is conducted. The result shows that the interior stress considering residual stress is much higher than that without considering residual stress. To verify the simulation accuracy of these two cases, the high-stress area locations in the simulation results are compared with the damage locations in physical bending fatigue test. The result illustrates that the simulation result considering the residual stress accords with the experimental result better. Therefore, the simulation result of the residual stress is reasonable, and it is necessary to consider residual stress in the simulation of the LGFT wheel.

scholarly journals The Effect of AC (alternating current) and DC (direct current) on Bend Testing Results of Low Carbon Steel Welding Joints

Teknomekanik ◽  
2020 ◽  
Vol 3 (2) ◽  
pp. 56-61
Author(s):  
Zetri Firmanda ◽  
Abdul Aziz ◽  
Bulkia Rahim
Keyword(s):  
Carbon Steel ◽  
Direct Current ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Alternating Current ◽  
Bend Test ◽  
Open Crack ◽  
Low Carbon ◽  
Bend Testing ◽  
Welding Joints

The purpose of this study was to determine the effect of alternating current (AC) and direct current (DC) on the bend testing results of low carbon steel welding joints. The results of this study are expected to determine the cracks that occur from the root bend and face bend testings in the AC and DC welding process. This study used experimental method, where the research was done by giving AC and direct polarity DC (DC-) SMAW welding treatments. The material used in this research was low carbon steel plate DIN 17100 Grade ST 44, thickness 10 with E7016 electrode type. The process of welding joints used a single V seam, strong current of 90A, and the welding position of 1G. The testing of welding joints was carried out by bend testing using the standard acceptance of AWS D1.1 root bend and face bend testing results. The results of the bend testing showed that the AC welding root bend test specimen held no cracks while the DC welding root bend test held cracks with incompelete penetration and open crack defects. On the contrary, the AC welding face bend test had open crack defects and in the DC welding face bend test was found a crack. Thus, there was a difference in the crack resistance of the welding joint from the types of current used through the root bend test and face bend test. Therefore, it can be summarized that AC welding is better for root welding and DC welding is good for capping welding.

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