Numerical and Experiment Study of Residual Stress and Strain in Multi-Pass GMA Welding

Abstract

There must selection an optimal of welding parameter and condition that reduces the risk of mechanical failures on weld structures.The residual stress and welding deformation have the large impact on the failure of welded structures.To achieve the required precision for welded structures, it is required to predict the welding distortions at the early stages.Therefore, this study uses 2DFinite Element Method (FEM) to predict residual stress and strain on thick SS400 steel metal plate. A birth and death technique is employed to control the each weld pass welding. Gas Metal Arc (GMA) welding experiment is also performed with similar welding condition to validate the FE results.The simulated and experiment results provide good evidence that heat input is main dependent on the welding parameter and residual stress and distortions are mainly affected by amount on heat input during each weld-pass.

Thermal and structural modelling of arc welding processes: A literature review

“…Welding stresses originate from the restrained welding distortion. Many research papers 24–51 describe the models used to find the welding distortion and welding residual stresses. To get the exact model, the field describes the specimen of metal needed to be able to change its volume and shape; along with this, properties of the materials are required like specific heat, plasticity, Poisson’s ratio and density.…”

“…The deposition of metal for each welding pass is controlled by employing a birth and death technique. 46 Thermal-mechanical analysis was applied using FE methods, to examine the thermo elasto-plastic conduct and figure the welding stresses in welded joints. The welding stresses on the shell of the weldments were calculated with the help of non-destructive technique X-ray diffraction and the predicted results were matched with the predicted results from FEA to validate the process.…”

Estimation of Residual Stress in Selective Laser Melting of a Zr-Based Amorphous Alloy

“…A thermal-mechanical coupled analysis model consisting of a cantilever and substrate was established by ABAQUS software (ABAQUS 6.10, Dassault, France), as shown in Figure 1 a. Gaussian distributed moving heat flux was applied via an ABAQUS subroutine DFLUX. The moving direction and velocity of the heat flux were controlled by a subroutine, and elements were activated step by step sequentially as the heat flux moved (“birth and death” technique [ 36 ]). In order to reduce computational costs and predict the results well, Alvarez et al [ 27 ] suggested a ratio between real manufacturing layers and model layer activation steps of 8 (48 real layers, activated in 6 steps).…”

Experimental Study of Distortion in Butt Welds of Mild Steel Plates and En-31 Plates Having Different Thickness and Weld Cross Sections

“…Chand R.R. et al (2013) [10], had done numerical and experiment study of residual stress and strain in multipass GMA welding. Through 2D FE simulations of five pass GMA welding was performed on the 16mm thick SS400 material, to determine residual stress, strain and deflection on the plate.…”