Welding Distortion Prediction in 5A06 Aluminum Alloy Complex Structure via Inherent Strain Method

Abstract

Finite element (FE) simulation with inherent deformation is an ideal and practical computational approach for predicting welding stress and distortion in the production of complex aluminum alloy structures. In this study, based on the thermal elasto-plastic analysis, FE models of multi-pass butt welds and T-type fillet welds were investigated to obtain the inherent strain distribution in a 5A06 aluminum alloy cylindrical structure. The angular distortion of the T-type joint was used to investigate the corresponding inherent strain mechanism. Moreover, a custom-designed experimental system was applied to clarify the magnitude of inherent deformation. With the mechanism investigation of welding-induced buckling by FE analysis using inherent deformation, an application for predicting and mitigating the welding buckling in fabrication of complex aluminum alloy structure was developed.

A stuffed Whipple shield for the Chinese space station

“…The yield strength of this material provided by CAST is 47 ksi (≈ 324 MPa). Values in the literature vary between 110 MPa and 340 MPa [32][33][34][35][36]. The rear wall material used for the ISS Columbus shield is aluminum alloy 2219-T851 [6].…”

Micro-nano structure and characterization in the nugget zone of Al-Cu-Mg alloy under friction stir processing

“…The higher shear stress also can induce higher strain. The original grain and subgrain boundaries in stir zone mainly appear to be replaced with fine, equiaxed recrystallized grains [14,15]. However, the structure ordering of some atoms of weld metal in the nugget zone might be restrained by higher shear stress and strain in this special physical condition.…”

Finite Element Analysis on Welding-Induced Distortion of Automotive Rear Chassis Component

“…When examining the deformation, residual stress, and metallic properties of the product after welding, a rigorous coupled thermal-structural analysis model must be adopted that strictly considers the thermal-mechanical-metallurgical properties despite excessive computational time and costs. To solely determine the product deformation after welding, it is realistic to adopt a simplified model such as the inherent deformation model, simplified mechanical model, strain as a direct boundary method, and thermal shrinkage model [18][19][20][21]. Such a model needs less analysis time and is consistent with the experimental results to some extent.…”