Abstract
A three-dimensional thermomechanical finite element (FE) analysis is carried out to model and predict the influence of welding sequence on the generation of distortions and residual stresses in large size T-joints. To simulate industrial welding conditions, the influence of nine welding sequences on the magnitude of distortion in both the plate and the stiffener was investigated. The addition of new material during welding was simulated using an element “birth and death” technique, while the moving welding arc was considered as a volumetric heat source with a double ellipsoidal distribution. The investigated material is a structural steel used for fabrication of large size structures in the hydroelectric industry. To calibrate the model and validate the simulation results, welding-induced distortion for one sequence was initially modeled and the results were compared with experimental measurements. The optimum welding sequences for the base plate and the reinforcement plate were determined. The results indicated also that the predicted distortions obtained from three-dimensional FE analysis are in reasonable agreement with experimental measurements.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Gery D, Long H, Maropoulos P (2005) Effects of welding speed, energy input and heat source distribution on temperature variations in butt joint welding. Mater Process Technol 167:393–401
Sattari-Far I, Javadi Y (2008) Influence of welding sequence on welding distortions in pipes. Press Vessel Pip 85:265–274
Barsoum Z, Lundbak A (2009) Simplified FE welding simulation of fillet welds—3D effects on the formation residual stresses. Eng Fail Anal 16:2281–2289
Kou S (2002) Welding metallurgy. Department of Materials Science and Engineering University of Wisconsin
Masubuchi K (1980) Analysis of welded structures. Massachusetts Institute of Technology, USA
Feng Z (2005) Processes and mechanisms of welding residual stress and distortion, Woodhead publishing
Lindgren L-E (2006) Numerical modeling of welding. Comput Methods Appl Mech Eng 195:6710–6736
Joy Varghese VM, Suresh MR, Siva Kumar D (2013) Int J Adv Manuf Technol 64:749–754
Schenk T, Richardson IM, Kraska M, Ohnimus S (2009) A study on the influence of clamping on welding distortion. Comput Mater Sci 46:999–1005
Zaeem MA, Nami MR, Kadivar MH (2007) Prediction of welding buckling distortion in a thin wall aluminium T joint. Comput Mater Sci 38:588–594
Anderson LF (2000) Residual stresses and deformations in steels structures. Department of Naval Architecture and Offshore Engineering, Technical University of Denmark, Lyngby
Deng D, Serizawa H, Murakawa H (2001) Theoretical prediction of welding distortion considering positioning and the gap between parts. Trans JWRI 30(2):89–96
Gannon L, Liu Y, Pegg N, Smith M (2010) Effect of welding sequence on residual stress and distortion in flat-bar stiffened plates. Mar Struct 23:385–404
MatWeb. Online materials information resource. <http://www.matweb.com/>
Barsoum Z, Barsoum I (2009) Residual stress effects on fatigue life of welded structures using LEFM. Eng Fail Anal 16:449–467
Deng D (2009) FEM prediction of welding residual stress and distortion in carbon steel considering phase transformation effects. Mater Des 30:359–366
Hansen J L (2003) Numerical modeling of welding induced stresses. PhD thesis, Technical University of Denmark
Deng D, Murakawa H (2008) Prediction of welding distortion and residual stress in a thin plate butt-welded joint. Comput Mater Sci 43:353–365
Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metall Mater Trans B 15:299–305
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Keivani, R., Jahazi, M., Pham, T. et al. Predicting residual stresses and distortion during multisequence welding of large size structures using FEM. Int J Adv Manuf Technol 73, 409–419 (2014). https://doi.org/10.1007/s00170-014-5833-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-5833-4