Thermal and Residual Stress Distributions in Inconel 625 Butt‐Welded Plates: Simulation and Experimental Validation

Abstract

Thermal and residual stress distributions induced by the gas tungsten arc welding (GTAW) process on Inconel 625 were studied using numerical simulation and experiments. A multi-pass welding model was developed that uses a volumetric heat source. Thermomechanical analysis is carried out to assess the Thermal and residual stress distributions. Experiments were carried out with 5 mm thick Inconel 625 plates. X-ray diffraction techniques were used to measure residual stresses, and IR thermometry was employed to capture the temperature values on the welded joints. Simulations were performed with ANSYS numerical code, and a close agreement was found between the predicted and experimentally measured residual stress. Thermal measurements were collected pass by pass from the analysis, and the agreement was 9.08%. The agreement between the measured and analysed residual stress was 11%.

Preliminary Investigation Into Mechanical Properties and Microstructural Behaviour of Inconel Alloy Under Welded and Unwelded Conditions

“…The residual stress formed at the welded joints of Inconel 625 alloy was studied through experimentation and simulation methods. Both the XRD technique and ANSYS numerical code showed a close relationship of results [19]. Inconel alloy had been successfully welded with titanium alloy by laser beam welding.…”

FEM-Based Thermogram Correction for Inconel 625 Joint Hardness Clustering

“…In the paper a limited approach was used, that was based only on bounding the simulation results with the shape of real welded joint and HAZ cross-section. As FEM modelling is generally used to predict the stress distribution in welded joints [28,29], it was applied in the research to obtain a reliable and accurate temperature distribution on the surface of the workpiece. Even using this limited approach it was found, that naïve application of theoretic values of thermal efficiency can lead unexpected results, when the temperature distribution remains unreliable.…”

Optimisation process parameters for Multipass GTAW dissimilar materials of SS316L to INCONEL625

“…Taguchi-based DOE is a useful statistical technique for optimising manufacturing process design, addressing manufacturing and production difficulties, establishing the optimal assembly method, etc., since it increases performance consistency and reduces susceptibility to uncontrolled variables. Using the Taguchi method [6][7][8][9] may cut down on the time spent conducting experiments while simultaneously raising the process's standard. The Taguchi approach has been widely used in various fields and regions over the last several years [10].…”