Numerical and experimental investigation on distribution of residual stress and the influence of heat treatment in multi-pass dissimilar welded rotor joint of alloy 617/10Cr steel

Kumar, Rajiv; Dey, H. C.; Pradhan, Arun Kumar; Albert, Shaju K.; Thakre, J. G.; Mahapatra, Manas Mohan; Pandey, Chandan

doi:10.1016/j.ijpvp.2022.104715

Cited by 28 publications

(16 citation statements)

References 25 publications

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“…Deep hole drilling (DHD) is a semi-destructive method used for measuring the through-thickness residual stresses based on strain relaxation methodology. This method estimates the locked-in stresses from the deformation of a reference hole following material removal [ 37 , 38 , 39 ]. The DHD process mainly involves four steps: (1) drilling of a reference hole; (2) measuring the hole diameter by an air probe; (3) trepanning the reference hole using EDM; and (4) re-measuring the hole diameter by an air probe [ 40 , 41 ].…”

Section: Resultsmentioning

confidence: 99%

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

et al. 2022

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Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on the arc welding process in which wire is melted by an electric arc and deposited layer by layer. Due to the cost and rate benefits over powder-based additive manufacturing technologies and other alternative heat sources such as laser and electron beams, the process is currently receiving much attention in the industrial production sector. The gas metal arc welded (GMAW) based WAAM process provides a higher deposition rate than other methods, making it suitable for additive manufacturing. The fabrication of mild steel (G3Si1), austenitic stainless steel (SS304), and a bimetallic sample of both materials were completed successfully using the GMAW based WAAM process. The microstructure characterization of the developed sample was conducted using optical and scanning electron microscopes. The interface reveals two discrete zones of mild steel and SS304 deposits without any weld defects. The hardness profile indicates a drastic increase in hardness near the interface, which is attributed to chromium migration from the SS304. The toughness of the sample was tested based on the Charpy Impact (ASTM D6110) test. The test reveals isotropy in both directions. The tensile strength of samples deposited by the WAAM technique measured slightly higher than the standard values of weld filament. The deep hole drilling (DHD) method was used to measure the residual stresses, and it was determined that the stresses are compressive in the mild steel portion and tensile in austenitic stainless steel portion, and that they vary throughout the thickness due to variation in the cooling rate at the inner and outer surfaces.

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Section: Resultsmentioning

confidence: 99%

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

et al. 2022

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“…A detailed description of the DHD method is described in the previously published work. 24,25 Furthermore, the mechanical and metallurgical studies were also done. Figure 3(a) and (b) shows the welded joint's top and bottom surfaces along the cross section of the weld.…”

Section: Methodsmentioning

confidence: 99%

“…where ε is creep strain, A and n is the creep constants, R is the universal gas constant, Q c is the creep activation energy, and T is the temperature in kelvin. 1,24,31 Results and discussion…”

Section: Stress Relaxation Modeling In Heat Treatmentmentioning

confidence: 99%

“…Heat loss to the surrounding atmosphere was assumed using Newton's law: where h c is the heat transfer coefficient taken as 15 × 10 − 6 .1em W / false( m m 2 .1em ∘ C false), T s is the temperature at the surface of the specimen, and T i is the room temperature which was taken as 28°C. 24,28 Temperatures for the solidus and liquidus were set at 1279°C and 1390°C, respectively. 24 To simulate the temperature field and determine the distribution of residual stress over the weld cross-section, discretization of the weld cross-section was performed.…”

Section: Fe Analysismentioning

confidence: 99%

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Residual stresses study in butt welded joint of Inconel 617 alloy and effect of post weld heat treatment on residual stresses

Kumar

Dey

Pradhan

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Distribution of weld-induced residual stress plays a significant effect on the service life of a welded component. The accumulation of high residual stress accelerates the crack propagation even if the crack is of microscopic level, reducing the service life of the welded component. Prior understanding of residual stress distribution can aid in the design of a component with an adequate factor of safety and reduce the probability of failure. In the present study, two separate circumferential butt welded pipes were fabricated using Alloy 617 and then subjected to post weld heat treatment) at 720°C and 980°C. The deep hole drilling method was used to measure the distribution of residual stress. The fabrication of the welded joint was done using the hot-wire TIG welding process. High welding speeds are possible with hot-wire tungsten inert gas (TIG) welding because it uses less heat than conventional TIG welding. Using hot-wire TIG welding, the welded joint's mechanical properties, such as hardness, are improved in addition to its metallurgical properties. The computational approach is provided to analyze temperature and residual stress fields in multi-pass TIG welds with different passes. Based on ABAQUS FEA software, a coupled thermomechanical computational approach was developed to analyze the residual stress distribution on the welded joint. A 3D finite element model for Alloy 617 tube was created to estimate the welding stress field in two separate multi-pass welded joints. Mixed hardening model (kinematic and isotropic) was used during the numerical analysis. The effectiveness of the computational approach was verified with experimental measurements. The magnitude of hoop and axial residual stresses were observed to be maximum at a depth of 6 mm from the upper surface. The stress gradient in the welded zone and heat-affected zone is dramatically reduced by 70–80% of the as-welded condition during the post weld heat treatment at 980°C.

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“…Nowadays, X80 is the most widely used micro-alloyed pipeline steel in oil and gas transportation [ 19 , 20 , 21 , 22 , 23 ], and it is required to be welded on site. The joint form on the pipeline is mainly butt girth weld [ 24 ], and the pipe needs to be assembled with an alignment device prior to welding. Owing to relatively the low machining accuracy of pipe grooves, the alignment precision is often difficult to guarantee.…”

Section: Introductionmentioning

confidence: 99%

Effect of Butt Gap on Stress Distribution and Carrying Capacity of X80 Pipeline Girth Weld

Zhu

Jia²,

et al. 2022

Materials

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An unstable assembly gap is detrimental to the formation and performance of the pipeline butt girth weld joint. Therefore, a numerical model of an 18.4 mm-thick X80 pipeline girth weld by a homogeneous body heat source was established to investigate the effect of the butt gap on the joint temperature and stress field, and carrying capacity. The accuracy of the simulation results was verified by measuring the welding thermal cycle with a thermocouple. The investigation results showed that the weld pool, heat-affected zone (HAZ) width, and maximum circumferential stress of the joint rose with the increase in the butt gap. The tensile stress unfavorable to the joint quality was mainly distributed in the weld metal and partial HAZ, and the distribution areas gradually expanded as the gap increased. The Von Mises stress peak value of the joint appeared in the order of 3 mm > 2 mm > 1 mm > 0 mm gap, reaching the maximum of 467.3 MPa (3 mm gap). This variation trend is directly related to the improvement in welding heat input with increasing butt gaps. The maximum Von Mises stress of the joint was positively correlated with the carrying capacity of the pipeline, which diminished as the butt gap enlarged. The pipeline carrying capacity reached 17.8 MPa for the joint with no butt gap, and dropped to 13.1 MPa for the joint with a 3 mm gap. The relationship between the carrying capacity (P) and butt gap (C) was described by P = −0.125C2 − 1.135C + 17.715, through which the pipeline carrying capacity with other butt gaps can be predicted.

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Numerical and experimental investigation on distribution of residual stress and the influence of heat treatment in multi-pass dissimilar welded rotor joint of alloy 617/10Cr steel

Cited by 28 publications

References 25 publications

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses

Residual stresses study in butt welded joint of Inconel 617 alloy and effect of post weld heat treatment on residual stresses

Effect of Butt Gap on Stress Distribution and Carrying Capacity of X80 Pipeline Girth Weld

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