Residual stresses have been numerically determined in welded joints. In this study, the numerical model is based on the coupling of different physical phenomena considering the thermal, mechanical and metallurgical nature of a welding process. The ABAQUS software program was used to perform the numerical simulations, based on the finite element method (FEM). The aspects related to the mathematical modeling of complex welding procedures were pondered with the FEM: variations in the physical and mechanical properties of the materials as a function of the temperature; the transience and the speed of the welding process, the material phase transformations; the different mechanisms of heat exchange with the environment (convection and radiation); all them associated with a high level of nonlinearity. The heat source used in this analytical model for heat supply was the double ellipsoid model proposed by Goldak, in which a 60 mm × 50 mm and 3 mm rectangular ASTM AH36 steel plate was used for the TIG process simulations. Throughout this work, the optimization of the welding procedures currently practiced in petrochemical and ship building industries can be applied to reduce the levels of residual stresses.
Residual stresses in a welded joint of ASTM A131 grade AH32 steel was measured either by the X-ray diffraction or by displacements of referenced points measured on a coordinate measuring machine before and after heat treatment. For all tests, the welding was performed with Shielded Metal Arc Welding, vertical-up position, by a certified welder. After welding, some specimens were subjected to marking, made through small holes evenly spaced and mapped on a coordinate measuring machine. After labeling, the samples were subjected to heat treatment at temperatures nearby recrystallization. After heat treatment, the samples were subjected to new measurements by coordinate measuring machine to evaluate the displacements of the points produced by the recrystallization. In parallel, residual stress measurements were made by XRD for validation of this new methodology. The results obtained either by X-ray or by coordinate measuring machine showed a good correlation between the two measurement methodologies employed.
The temperature field serves as the basis for predicting levels of residual stress in a welded joint. The aspects related to the mathematical modeling of complex welding procedures were pondered with the FEM: variations in the physical and mechanical properties of the materials as a function of the temperature, the transience and the speed of the welding process, the material phase transformations, the different mechanisms of heat exchange with the environment (convection and radiation), all them associated with a high level of nonlinearity. The heat source used in this analytical model for heat supply was the double ellipsoid model proposed by Goldak (2005), in which a 60 mm x 50 mm and 3 mm rectangular ASTM AH36 steel plate was used for the TIG process simulations. It was made a comparison of temperature fields for three different values of process efficiency (60%, 70% and 80%). The results showed many differences in the temperature fields following changes in the levels of residual stresses which will be determined in further studies.
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