Hardness prediction based on microstructure evolution and residual stress evaluation during high tensile thick plate butt welding

Zhou, Hong; Zhang, Qingya; Yi, Bin; Wang, Jiangchao

doi:10.1016/j.ijnaoe.2019.09.004

Cited by 26 publications

(16 citation statements)

References 18 publications

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“…Simulation results [170] revealed that the final residual stress and the welding distortion in low carbon steel do not seem to be influenced by the solid-state phase transformation. However, for the medium carbon steel, the final residual stresses and the welding distortion seem to be significantly affected by the martensitic transformation [171].…”

Section: Numerical Modelingmentioning

confidence: 93%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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Welding is a major manufacturing process that joins two or more pieces of materials together through heating/mixing them followed by cooling/solidification. The goal of welding manufacturing is to join materials together to meet service requirements at lowest costs. Advanced welding manufacturing is to use scientific methods to realize this goal. This paper views advanced welding manufacturing as a three step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the welding parameters by adjusting the welding parameters based on such real-time sensing and feedback control. The paper analyzes how these three steps depend on process properties/capabilities, process innovations, predictive models, numerical models for fluid dynamics, numerical models for structures, real-time sensing, and dynamic control. The paper also identifies the challenges in obtaining ideal solutions and reviews/analyzes the existing efforts toward better solutions. Special attention and analysis have been given to (1) gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) as benchmark processes for penetration and materials filling; (2) keyhole plasma arc welding (PAW), keyhole-tungsten inert gas (K-TIG), and keyhole laser welding as improved/capable penetrative processes; (3) friction stir welding (FSW) ......

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Section: Numerical Modelingmentioning

confidence: 93%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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“…Welding thermal cycle was an essential input parameter for predicting microstructure evolution and hardness in multi-pass butt joint of Q690 HSS, which was obtained using the in-house code. 18,21–22 The in-house code used for thermal analysis was programmed by FORTRAN, and then compiled with Intel Parallel Studio XE 2011 based on the platform of Ubuntu 14.04 OS and Dell PowerEdge T420 Server. 21 What is more, the parallel computation technology with eight threads was used to improve the computation efficiency.…”

Section: Computational Analysismentioning

confidence: 99%

“…Based on the heat conduction theory and temperature-dependent material thermal physical properties, the welding thermal cycle at each node in the finite element model can be calculated by solving the transient nonlinear heat transfer equation according to the welding conditions. 18,[21][22][23][24] The body heat source model with uniform power density was widely used to simulate the heat source of welding arc. The power density was determined by the welding current, welding voltage, travel speed, and the heat efficiency of welding arc.…”

Section: Thermal Analysis With Femmentioning

confidence: 99%

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Microstructure analysis and hardness prediction based on microstructure evolution theory in multi-pass welded joint

Zhang

Zhuo

Zhou

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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During multi-pass butt-welding of high-strength steel (HSS) thick plate, it is difficult to estimate the hardness performance of thick weld since multi thermal cycles can drive complex microstructure evolution. In this study, butt-welded joint of 75 mm-thick Q690 HSS was prepared by multi-pass shielded metal arc welding (SMAW) in advance, meanwhile experiments were carried out to characterize microstructure and measure hardness distribution in butt-welded joint. Then the welding temperature history of butt-welded joint was numerically examined. Based on the irreversibility of Martensite and Bainite, the microstructure evolution model was modified to predict the complicated microstructure evolution in multi-pass welded joint. Compared with experimental data, the validity of modified microstructure evolution model was verified. With the application of simulated thermal cycles and material chemical compositions as input parameters, volume fraction distribution of each phase was obtained by modified microstructure evolution model and hardness value was calculated by hardenability algorithm. Both experimental and predicted results exhibited that microstructure in weld metal (WM) is mainly composed of granular Bainite with a small amount of Ferrite and Martensite, and heat-affected zone (HAZ) consists of predominantly lath Martensite. Hardness distribution in butt-welded joint obtained by the prediction method is in accordance with the measurement. Average hardness value in WM and BM is 290 VPN and 250 VPN. A sharp decrease in HAZ hardness can be found from the fusion line to base metal (BM). The maximal value is in the HAZ close to fusion line and the corresponding prediction deviation is 6%.

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“…However, for the medium-carbon steel, the final residual stresses and the welding distortion seem to be significantly affected by the martensitic transformation (Refs. 88,89).…”

Section: Phase Transformation Modelingmentioning

confidence: 99%

Recent Advances in the Prediction of Weld Residual Stress and Distortion - Part 1

Yang¹

2021

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Residual stresses and distortions are the result of complex interactions between welding heat input, the material’s high-temperature response, and joint constraint conditions. Both weld residual stress and distortion can significantly impair the performance and reliability of welded structures. In the past two decades, there have been many significant and exciting developments in the prediction and mitigation of weld residual stress and distortion. This paper reviews the recent advances in the prediction of weld residual stress and distortion by focusing on the numerical modeling theory and methods. The prediction methods covered in this paper include a thermo-mechanical-metallurgical method, simplified analysis methods, friction stir welding modeling methods, buckling distortion prediction methods, a welding cloud computational method, integrated manufacturing process modeling, and integrated computational materials engineering (ICME) weld modeling. Remaining challenges and new developments are also discussed to guide future predictions of weld residual stress and distortion.

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Hardness prediction based on microstructure evolution and residual stress evaluation during high tensile thick plate butt welding

Cited by 26 publications

References 18 publications

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Microstructure analysis and hardness prediction based on microstructure evolution theory in multi-pass welded joint

Recent Advances in the Prediction of Weld Residual Stress and Distortion - Part 1

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