Thermal-Structural Plasma Gouging Simulation for Welding Repair

Abstract

Numerical simulations are commonly employed for comprehending and prognosticating welding procedures. However, repair often requires supplementary actions such as gouging for defect removal. Thermal cycles and nonuniform expansion and contraction of the base metal can engender internal and residual stresses in the gouged region. Residual stresses can wield influence over mechanical properties, thereby underscoring the necessity for their investigation. This study endeavors to establish a numerical method to simulate gouging while devising a rationale for thermal cutting processes. The model was validated by comparing computational and experimental results, which showed good agreement. Mechanical simulation unveiled residual stresses characterized by modest magnitude. This methodology can prevent mechanical failures in repaired components by providing valuable insights into the effects of the gouging process.