Effect of Plate Thickness and Weld Position on Distortion and Residual Stress of Welded Structural Steel

2011 ◽  
Vol 689 ◽  
pp. 296-301 ◽  
Author(s):  
Muhammad Anis ◽  
Winarto
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Structural Steel ◽  
Plate Thickness ◽  
Welding Process ◽  
Diffraction Method ◽  
Longitudinal Direction ◽  
Major Effect ◽  
Angular Distortion ◽  
Vertical Position

Residual stresses are generated as a result of non-uniform temperature distribution during welding and particularly cooling process during fabrication of the welded parts. Residual stresses have a major effect on the overall performance of a component in service. In this instant, the residual stress in the form of angular distortion is primarily caused by shrinkage on longitudinal and transversal direction. Several single v-butt joints on structural steel plates of SS400 are investigated by using different plate thickness and welding positions (1G and 3G). GMAW method was used in the welding process. Measurement of residual stress was carried out on a plate with the thickness of 16 mm on longitudinal, transversal and normal direction by using neutron diffraction method. Results showed that the angular distortion of the welded plates increase with the increase of plate thickness. Welding by vertical position (3G position) resulted in a bigger angular distortion compared to flat position (1G position). The distribution of residual stress varied between tension and compression residual stress along welded area with the range of -10 mm to 10 mm. Measurement of residual stress on the longitudinal direction has the greatest value among two other directions.

Estimation of Residual Stresses in Steel Welded Joints Using Three Dimensional Finite Element Analysis

2018 ◽  
Author(s):  
Shivdayal Patel ◽  
B. P. Patel ◽  
Suhail Ahmad
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Welding Speed ◽  
Welded Joints ◽  
Plate Thickness ◽  
Welding Process ◽  
Element Analysis

Welding is one of the most used joining methods in the ship industry. However, residual stresses are induced in the welded joints due to the rapid heating and cooling leading to inhomogenously distributed dimensional changes and non-uniform plastic and thermal strains. A number of factors, such as welding speed, boundary conditions, weld geometry, weld thickness, welding current/voltage, number of weld passes, pre-/post-heating etc, influence the residual stress distribution. The main aim of this work is to estimate the residual stresses in welded joints through finite element analysis and to investigate the effects of boundary conditions, welding speed and plate thickness on through the thickness/surface distributions of residual stresses. The welding process is simulated using 3D Finite element model in ABAQUS FE software in two steps: 1. Transient thermal analysis and 2. Quasi-static thermo-elasto-plastic analysis. The normal residual stresses along and across the weld in the weld tow region are found to be significant with nonlinear distribution. The residual stresses increase with the increase in the thickness of the plates being welded. The nature of the normal residual stress along the weld is found to be tensile-compressive-tensile and the nature of normal residual stress across the weld is found to be tensile along the thickness direction.

Measurement of residual stresses in T-plate weldments

2003 ◽  
Vol 38 (4) ◽  
pp. 349-365 ◽  
Author(s):  
R. C Wimpory ◽  
P. S May ◽  
N. P O'Dowd ◽  
G. A Webster ◽  
D J Smith ◽  
...  
Keyword(s):  
Residual Stress ◽  
Neutron Diffraction ◽  
Plastic Zone ◽  
Residual Stresses ◽  
Plate Thickness ◽  
Welding Process ◽  
Plastic Zone Size ◽  
Hole Drilling ◽  
Stress Distributions ◽  
Premature Failure

Tensile welding residual stresses can, in combination with operating stresses, lead to premature failure of components by fatigue and/or fracture. It is therefore important that welding residual stresses are accounted for in design and assessment of engineering components and structures. In this work residual stress distributions, obtained from measurements on a number of ferritic steel T-plate weldments using the neutron diffraction technique and the deep-hole drilling method, are presented. It has been found that the residual stress distributions for three different plate sizes are of similar shape when distances are normalized by plate thickness. It has also been found that the conservatisms in residual stress profiles recommended in current fracture mechanics-based safety assessment procedures can be significant—of yield strength magnitude in certain cases. Based on the data presented here a new, less-conservative transverse residual stress upper bound distribution is proposed for the T-plate weldment geometry. The extent of the plastic zone developed during the welding process has also been estimated by use of Vickers hardness and neutron diffraction measurements. It has been found that the measured plastic zone sizes are considerably smaller than those predicted by existing methods. The implications of the use of the plastic zone size as an indicator of the residual stress distributions are discussed.

Residual Stresses in Butt Welding of Two Circular Pipes: An Experimental and Numerical Investigation

2014 ◽  
Author(s):  
Gurinder Singh Brar
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Welding Process ◽  
Diffraction Method ◽  
Element Model ◽  
X Ray Diffraction ◽  
X Ray

Welding is a reliable and efficient joining process in which the coalescence of metals is achieved by fusion. Welding is carried out with a very complex thermal cycle which results in irreversible elastic-plastic deformation and residual stresses in and around fusion zone and heat affected zone (HAZ). A residual stress due to welding arises from the differential heating of the plates due to the weld heat source. Residual stresses may be an advantage or disadvantage in structural components depending on their nature and magnitude. The beneficial effect of these compressive stresses have been widely used in industry as these are believed to increase fatigue strength of the component and reduce stress corrosion cracking and brittle fracture. But due to the presence of residual stresses in and around the weld zone the strength and life of the component is also reduced. To understand the behavior of residual stresses, two 10 mm thick Fe410WC mild steel plates are butt welded using the Metal Active Gas (MAG) process. An experimental method (X-ray diffraction) and numerical analysis (finite element analysis) were then carried out to calculate the residual stress values in the welded plates. Three types of V-butt weld joint — two-pass, three-pass and four-pass were considered in this study. In multi-pass welding operation the residual stress pattern developed in the material changes with each weld pass. In X-ray diffraction method, the residual stresses were derived from the elastic strain measurements using a Young’s modulus value of 210 GPa and Poisson’s ratio of 0.3. Finite element method based, SolidWorks software was used to develop coupled thermal-mechanical three dimension finite element model. The finite element model was evaluated for the transient temperatures and residual stresses during welding. Also variations of the physical and mechanical properties of material with the temperature were taken into account. The numerical results for peak transverse residual stresses attained in the welded plates for two-pass, three-pass and four-pass welded joint were 67.7 N/mm2, 58.6 N/mm2, and 48.1 N/mm2 respectively. The peak temperature attained during welding process comes out to be 970°C for two-pass weld, 820.8°C for three-pass weld and 651.9°C for four-pass weld. It can be concluded that due to increase in the number of passes during welding process or deposition weld beads, the residual stresses and temperature distribution decrease. Also, the results obtained by finite element method agree well with those from experimental X-ray diffraction method.

Residual Stress and Shape Distortion in High-Strength Tool Steels

1967 ◽  
Vol 11 ◽  
pp. 411-417
Author(s):  
L. B. Gulbransen ◽  
A. K. Dhingra
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Residual Stresses ◽  
Tool Steel ◽  
High Performance ◽  
Diffraction Method ◽  
High Strength ◽  
Angular Distortion ◽  
Shape Distortion ◽  
Heat Treated

AbstractOne of the major problems that has plagued the tool and die maker for many years and more recently has come to the attention of the manufacturer of missiles and high-performance aircraft is the problem of shape distortion which occurs during heat treatment in the high-strength tool and die steels. Not only is shape distortion a problem in the heat treatment and use of these materials, but the origin of shape distortion has been a controversial issue among metallurgists for many years. The quantitative measurement of shape distortion on heat-treated steels is simply carried out hy machining standard shape samples, in this case, an L-shaped sample, and making a measurement of the variation after heat treatment from the 90° of the original 90° angle of the L. It is usually assumed that relief of residual stresses in heat-treated parts will occur by the shape changes which have been described above; however, it has been demonstrated that elastic residual stresses may still be present in heat-treated parts that have been tempered and theoretically should be stress free. By a very straightforward and simple application of the backreflection X-ray diffraction method for residual-stress determination, a very striking relationship has been demonstrated between the shape (angular) distortion of both A2 tool steel (air hardening) and O1 tool steel (oil hardening) and the residualstress pattern of these steels. Conversely, one could presumably utilize residualstress data at changes in cross section to estimate semiquantitatively the amount of shape distortion which occurs in rather complex parts.

Computational Method to Assess the Residual Stresses of Thick Plate Joined by Two-Pole Tandem EGW in Marine Vessels

2009 ◽  
Author(s):  
Jang Hyun Lee ◽  
Se Yun Hwang ◽  
Yong Sik Yang
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Thick Plate ◽  
Control Process ◽  
Diffraction Method ◽  
Butt Joint ◽  
Computational Method ◽  
Vertical Position ◽  
Element Analysis ◽  
Thick Plates

Shear strakes or deck plates of large container carrier and FPSO vessels are joined by ultra-thick plates whose thickness is more than 60mm. Traditionally FCAW (Flux-Core Arc Welding) has been used to join the ultra-thick plates. However, FCAW has been replaced with EGW (Electro-Gas Welding) since the welding efficiency of EGW is higher than that of FCAW. Two-pole EGW has been applied to vertical position welding by several shipyards. EGW requires one or two layers of bead whereas FCAW requires more than 20 layers of weld bead in thick welding. However it uses higher heat input than FCAW. Therefore high welding residual stresses are generated by EGW. It is known that the high residual stress may shorten the fatigue strength of the joined structure. The residual stress should be investigated when EGW is applied to the thick plate joining. Present study explains a computational method to analyze the residual stress of EGW in the thick plates. Based upon the FEA (finite element analysis), both profile and level of the residual stresses are studied for EH40 TMCP (Thermo-Mechanical Control Process) steel plates with thickness of 80mm. Also, peculiar stresses of butt joint specimens are measured by X-ray diffraction method to assure the results of the FEA model.

X-Ray Stress Measurement of Fiber Reinforced Plastics Composite Material

2007 ◽  
Vol 353-358 ◽  
pp. 2423-2426 ◽  
Author(s):  
Nishida Masayuki ◽  
Hanabusa Takao ◽  
Yasukazu Ikeuchi
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Diffraction Method ◽  
Longitudinal Direction ◽  
Residual Stress Measurement ◽  
Fiber Reinforced ◽  
Transmission Method ◽  
Polyethylene Matrix ◽  
X Ray

X-ray stress measurement with sin2ψ method is one of useful tools to detect residual stresses in manufactured products. In this study, the residual stresses in the tungsten fiber reinforced polyethylene composite were examined by X-ray stress measurement technique. The transmission diffraction method was employed in residual stress measurement of polyethylene matrix. The X-ray elastic constant of high density polyethylene (HDPE) which formed matrix of the composite was estimated before residual stress measurement. The results of sin2ψ diagram with transmission method show good linearity under the several tensile loading. After that the residual stresses in the composite were investigated for HDPE matrix phase. From the measurement results, the tensile residual stresses existed in fiber longitudinal direction and compressive ones in transverse direction for HDPE matrix.

scholarly journals Residual stresses in thermite welded rails: significance of additional forging

2020 ◽  
Vol 64 (7) ◽  
pp. 1195-1212
Author(s):  
B. Lennart Josefson ◽  
R. Bisschop ◽  
M. Messaadi ◽  
J. Hantusch
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Weld Metal ◽  
Welding Process ◽  
Surface Zone ◽  
Fe Model ◽  
Uneven Surface ◽  
Residual Stress Field ◽  
High Dynamic

Abstract The aluminothermic welding (ATW) process is the most commonly used welding process for welding rails (track) in the field. The large amount of weld metal added in the ATW process may result in a wide uneven surface zone on the rail head, which may, in rare cases, lead to irregularities in wear and plastic deformation due to high dynamic wheel-rail forces as wheels pass. The present paper studies the introduction of additional forging to the ATW process, intended to reduce the width of the zone affected by the heat input, while not creating a more detrimental residual stress field. Simulations using a novel thermo-mechanical FE model of the ATW process show that addition of a forging pressure leads to a somewhat smaller width of the zone affected by heat. This is also found in a metallurgical examination, showing that this zone (weld metal and heat-affected zone) is fully pearlitic. Only marginal differences are found in the residual stress field when additional forging is applied. In both cases, large tensile residual stresses are found in the rail web at the weld. Additional forging may increase the risk of hot cracking due to an increase in plastic strains within the welded area.

Residual Stresses in Steel and Zirconium Weldments

1997 ◽  
Vol 119 (2) ◽  
pp. 137-141 ◽  
Author(s):  
J. H. Root ◽  
C. E. Coleman ◽  
J. W. Bowden ◽  
M. Hayashi
Keyword(s):  
Residual Stress ◽  
Electron Beam ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Prolonged Exposure ◽  
Electron Beam Welding ◽  
Three Dimensional ◽  
Diffraction Method ◽  
Outer Diameter ◽  
Stress Relieving

Three-dimensional scans of residual stress within intact weldments provide insight into the consequences of various welding techniques and stress-relieving procedures. The neutron diffraction method for nondestructive evaluation of residual stresses has been applied to a circumferential weld in a ferritic steel pipe of outer diameter 114 mm and thickness 8.6 mm. The maximum tensile stresses, 250 MPa in the hoop direction, are found at mid-thickness of the fusion zone. The residual stresses approach zero within 20 mm from the weld center. The residual stresses caused by welding zirconium alloy components are partially to blame for failures due to delayed hydride cracking. Neutron diffraction measurements in a GTA-welded Zr-2.5Nb plate have shown that heat treatment at 530°C for 1 h reduces the longitudinal residual strain by 60 percent. Neutron diffraction has also been used to scan the residual stresses near circumferential electron beam welds in irradiated and unirradiated Zr-2.5Nb pressure tubes. The residual stresses due to electron beam welding appear to be lower than 130 MPa, even in the as-welded state. No significant changes occur in the residual stress pattern of the electron-beam welded tube, during a prolonged exposure to thermal neutrons and the temperatures typical of an operating nuclear reactor.

scholarly journals Residual Stresses Induced by Surface Working and Their Improvement by Emery Paper Polishing

2020 ◽  
Vol 4 (2) ◽  
pp. 21
Author(s):  
Makoto Hayashi
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Fatigue Strength ◽  
Residual Stresses ◽  
Diffraction Method ◽  
304 Stainless Steel ◽  
Heat Treated ◽  
Emery Paper ◽  
Type 304 ◽  
Type 304 Stainless Steel

In many of machine parts and structural components, materials surface would be worked. In this study, residual stresses on the surfaces were measured by X-ray diffraction method, and effects of surface working on the residual stresses were examined. In case of lathe machining of type 304 stainless steel bar, the residual stresses in circumferential directions are tensile, and those in axial directions are almost compressive. Highly tensile residual stresses in the circumferential directions were improved by emery paper polishing. 10 to 20 times of polishing changes high tensile residual stresses to compressive residual stresses. In the case of shot peening on a type 304 stainless steel plate, the compressive residual stress inside is several hundred MPa lower than that on the surface. By applying the emery paper polishing to the shot peened surface 10 or 20 times, the residual stress on the surface is improved to −700 MPa. While fatigue strength at 288 °C in the air of the shot peened material is 30 MPa higher than solution heat treated and electro-polished material, the fatigue strength of the shot peened and followed by emery paper polished material is 60 MPa higher. Thus, the emery paper polishing is simple and a very effective process for improvement of the residual stresses.

Characterization and Evaluation of Mechanical Properties and Residual Stress in Aluminum-Magnesium Alloys Welded by the FSW Process

2020 ◽  
Vol 1012 ◽  
pp. 349-353
Author(s):  
D.B. Colaço ◽  
M.A. Ribeiro ◽  
T.M. Maciel ◽  
R.H.F. de Melo
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Residual Stresses ◽  
Welding Process ◽  
Bending Test ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Friction Stir ◽  
Aluminum Magnesium Alloys

The demand for lighter materials with suitable mechanical properties and a high resistance to corrosion has been increasing in the industries. Therefore, aluminum appears as an alternative due to its set of properties. The aim of this work was to evaluate residual stress levels and mechanical properties of welded joints of Aluminum-Magnesium alloy AA 5083-O using the Friction Stir Welding process. For mechanical characterization were performed a uniaxial tensile test, Vickers hardness, bending test and, finally, the determination of residual stresses. It was concluded that welding by FSW process with an angle of inclination of the tool at 3o, established better results due to better mixing of materials. The best results of tensile strength and a lower level of residual stresses were obtained using a tool rotation speed of 340 RPM with welding advance speed of 180 mm/min and 70 mm/min.

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