Determination of welding deformation in fillet-welded joint by means of numerical simulation and comparison with experimental measurements
TL;DR: In this article, a 3-D thermal elastic plastic finite element computational procedure is developed to precisely predict welding deformation by numerical method, and the simulated results are in a good agreement with the experimental measurements.
About: This article is published in Journal of Materials Processing Technology.The article was published on 2007-03-23. It has received 208 citations till now. The article focuses on the topics: Welding & Fillet weld.
Citations
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TL;DR: In this paper, a three-dimensional, thermo-elastic-plastic, large deformation finite element method (FEM) is used to simulate welding distortion in a low carbon steel butt-welded joint with 1mm thickness.
315 citations
TL;DR: In this article, the influence of welding sequences on the distribution of residual stress and distortion generated when welding a flat-bar stiffener to a steel plate was investigated and their effects on the ultimate strength of the stiffened plate under uniaxial compression were discussed.
147 citations
TL;DR: In this paper, a prediction method of welding distortion, which combines thermo-elastic-plastic finite element method (FEM) and large deformation elastic FEM based on inherent strain theory and interface element method, was developed.
126 citations
TL;DR: In this paper, a numerical and experimental study of residual stresses and distortions induced by the T-joint welding of two plates is performed by using a shell/three-dimensional modeling technique to improve both computational efficiency and the accuracy.
126 citations
TL;DR: In this paper, the influence of thermo-mechanical material properties of different steel grades (S355-S960) on welding residual stresses and angular distortion in T-fillet joints was investigated.
120 citations
References
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TL;DR: In this article, a three-dimensional finite element model has been developed to simulate the laser welding process and predict laser welded panel distortions, which takes into account thermal, metallurgical and mechanical aspects.
302 citations
Additional excerpts
...[5] S....
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...Until now, a lot of analytical and numerical models have been roposed for predicting welding distortion in butt joint, and a umber of databases have also been established [1–6]....
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Book•
01 May 1992
TL;DR: In this paper, the authors present a model for welding temperature fields and the effect of melting-off and fusion on the resulting heat field, as well as the effects of welding residual stresses.
Abstract: 1 Introduction.- 1.1 Scope and structuring of contents.- 1.2 Weldability analysis.- 1.3 Residual stresses.- 1.4 Welding residual stresses.- 1.5 Welding residual stress fields.- 1.6 Type examples.- 1.7 Welding deformations.- 1.8 References to related books.- 1.9 Presentation aspects.- 2 Welding temperature fields.- 2.1 Fundamentals.- 2.1.1 Welding heat sources.- 2.1.1.1 Significance of welding temperature fields.- 2.1.1.2 Types of welding heat sources.- 2.1.1.3 Output of welding heat sources.- 2.1.2 Heat propagation laws.- 2.1.2.1 Law of heat conduction.- 2.1.2.2 Law of heat transfer by convection.- 2.1.2.3 Law of heat transfer by radiation.- 2.1.2.4 Field equation of heat conduction.- 2.1.2.5 Initial and boundary conditions.- 2.1.2.6 Thermal material characteristic values.- 2.1.3 Model simplifications relating to geometry and heat input.- 2.1.3.1 Necessity for simplifications.- 2.1.3.2 Simplifications of the geometry.- 2.1.3.3 Spatial simplifications of the heat source.- 2.1.3.4 Time simplifications of heat source.- 2.1.3.5 User questions addressing welding temperature fields.- 2.1.3.6 Numerical solution and comparison with experiments.- 2.2 Global temperature fields.- 2.2.1 Momentary stationary sources.- 2.2.1.1 Momentary point source on the semi-infinite solid.- 2.2.1.2 Momentary line source in the infinite plate.- 2.2.1.3 Momentary area source in the infinite rod.- 2.2.2 Continuous stationary and moving sources.- 2.2.2.1 Moving point source on the semi-infinite solid.- 2.2.2.2 Moving line source in the infinite plate.- 2.2.2.3 Moving area source in the infinite rod.- 2.2.3 Gaussian distribution sources.- 2.2.3.1 Stationary and moving circular source on the semi-infinite solid.- 2.2.3.2 Stationary and moving circular source in the infinite plate.- 2.2.3.3 Stationary strip source in the infinite plate.- 2.2.4 Rapidly moving high-power sources.- 2.2.4.1 Rapidly moving high-power source on the semi-infinite solid.- 2.2.4.2 Rapidly moving high-power source in the infinite plate.- 2.2.5 Heat saturation and temperature equalization.- 2.2.6 Effect of finite dimensions.- 2.2.7 Finite element solution.- 2.2.7.1 Fundamentals.- 2.2.7.2 Ring element model.- 2.2.7.3 Plate element models.- 2.3 Local heat effect on the fusion zone.- 2.3.1 Electric arc as a welding heat source.- 2.3.1.1 Physical-technical fundamentals.- 2.3.1.2 Heat balance and heat source density.- 2.3.1.3 Heat conduction modelling of fusion welding.- 2.3.1.3.1 Melting of the electrode.- 2.3.1.3.2 Fusion of the base metal.- 2.3.1.3.3 Interaction of melting-off and fusion.- 2.3.1.4 Weld pool modelling.- 2.3.1.4.1 Weld pool physics.- 2.3.1.4.2 Welding arc modelling.- 2.3.1.4.3 Hydrostatic surface tension modelling.- 2.3.1.4.4 Hydrodynamic weld pool modelling.- 2.3.1.4.5 Hydrostatic weld shape modelling.- 2.3.1.4.6 Keyhole modelling.- 2.3.2 Flame as a welding heat source.- 2.3.2.1 Physical-technical fundamentals.- 2.3.2.2 Heat balance and heat flow density.- 2.3.3 Resistance heating of weld spots.- 2.3.4 Heat generation in friction welding.- 2.4 Local heat effect on the base metal.- 2.4.1 Microstructural transformation in the heat-affected zone.- 2.4.1.1 Thermal cycle and microstructure.- 2.4.1.2 Time-temperature transformation diagrams.- 2.4.1.3 Evaluation of time-temperature transformation diagrams.- 2.4.2 Modelling of microstructural transformation.- 2.4.3 Cooling rate, cooling time and austenitizing time in single-pass welding.- 2.4.3.1 Cooling rate in solids and thin plates.- 2.4.3.2 Cooling rate in thick plates.- 2.4.3.3 Cooling time in solids and plates.- 2.4.3.4 Austenitizing time in solids and plates.- 2.4.4 Temperature cycles in multi-pass welding.- 2.5 Hydrogen diffusion.- 3 Welding residual stress and distortion.- 3.1 Fundamentals.- 3.1.1 Temperature field as the basis.- 3.1.2 Elastic thermal stress field.- 3.1.3 Elastic-plastic thermal stress field.- 3.1.4 Basic equations of thermomechanics.- 3.1.5 Thermomechanical material characteristic values.- 3.2 Finite element models.- 3.2.1 Intelligent solution.- 3.2.2 Rod element model.- 3.2.3 Ring element model.- 3.2.4 Membrane plate element model in the plate plane.- 3.2.5 Membrane plate element model in the cross-section.- 3.2.6 Solid element model.- 3.3 Shrinkage force and stress source models.- 3.3.1 Longitudinal shrinkage force model.- 3.3.2 Transverse shrinkage force model.- 3.3.3 Application to cylindrical and spherical shells.- 3.3.4 Residual stress source model.- 3.4 Overview of welding residual stresses.- 3.4.1 General statements.- 3.4.2 Weld-longitudinal residual stresses.- 3.4.3 Weld-transverse residual stresses.- 3.4.4 Residual stresses after spot-welding, cladding, and flame cutting.- 3.5 Welding distortion.- 3.5.1 Model simplifications.- 3.5.2 Transverse shrinkage and groove transverse off-set.- 3.5.3 Longitudinal and bending shrinkage.- 3.5.4 Angular shrinkage and twisting distortion.- 3.5.5 Warpage of thin-walled welded components.- 3.6 Measuring methods for residual stress and distortion.- 3.6.1 Significance of test and measurement.- 3.6.2 Strain and displacement measurement during welding.- 3.6.3 Destructive residual stress measurement.- 3.6.3.1 Measurement of uniaxial welding residual stresses.- 3.6.3.2 Measurement of biaxial welding residual stresses.- 3.6.3.3 Measurement of triaxial welding residual stresses.- 3.6.4 Non-destructive residual stress measurement.- 3.6.5 Distortion measurement after welding.- 3.6.6 Similarity relations.- 4 Reduction of welding residual stresses and distortion.- 4.1 Necessities and kinds of measures.- 4.2 Design measures.- 4.3 Material measures.- 4.3.1 Starting points.- 4.3.2 Material characteristic values in the field equations.- 4.3.3 Traditional consideration of the influence of the material.- 4.3.4 Derivation of novel welding suitability indices.- 4.4 Manufacturing measures.- 4.4.1 Starting points.- 4.4.2 Measures prior to and during welding.- 4.4.2.1 Overview.- 4.4.2.2 General measures.- 4.4.2.3 Weld-specific measures.- 4.4.2.4 Thermal measures.- 4.4.2.5 Mechanical measures.- 4.4.2.6 Typical applications.- 4.4.3 Post-weld measures.- 4.4.3.1 Overview.- 4.4.3.2 Hot stress relieving (annealing for stress relief).- 4.4.3.2.1 Hot stress relieving in practice and relevant codes.- 4.4.3.2.2 Stress relaxation tests.- 4.4.3.2.3 Microstructural change during hot stress relieving.- 4.4.3.2.4 Equivalence of annealing temperature and annealing time.- 4.4.3.2.5 Creep laws and creep theories relating to hot stress relieving.- 4.4.3.2.6 Analysis examples and experimental results relating to hot stress relieving.- 4.4.3.3 Cold stress relieving (cold stretching, flame and vibration stress relieving).- 4.4.3.3.1 Rod element model for cold stretching.- 4.4.3.3.2 Notch and crack mechanics of cold stretching.- 4.4.3.3.3 Cold stretching in practice.- 4.4.3.3.4 Flame and induction stress relieving.- 4.4.3.3.5 Vibration stress relieving.- 4.4.3.4 Hammering, rolling, spot compression and spot heating.- 4.4.3.5 Hot, cold and flame straightening.- 5 Survey of strength effects of welding.- 5.1 Methodical and systematical points of view.- 5.2 Hot and cold cracks.- 5.3 Ductile fracture.- 5.4 Brittle fracture.- 5.5 Lamellar tearing type fracture.- 5.6 Creep fracture.- 5.7 Fatigue fracture.- 5.8 Geometrical instability.- 5.9 Corrosion and wear.- 5.10 Strength reduction during welding.
245 citations
TL;DR: In this article, the authors describe the thermal elasto-plastic analysis using finite element techniques to analyse the thermomechanical behavior and evaluate the residual stresses and angular distortions of the T-joint in fillet welds.
193 citations
"Determination of welding deformatio..." refers background in this paper
...However, nly very limited literatures describing welding deformation of llet welds are available [7,8]....
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01 Dec 1989-Metallurgical and Materials Transactions B-process Metallurgy and Materials Processing Science
TL;DR: In this paper, a 3D steady-state thermal model of the gas metal arc (GMA) welding process has been formulated for a moving coordinate framework and solved using the finite-element method.
Abstract: Mathematical models of the gas metal arc (GMA) welding process may be used to study the influence of various welding parameters on weld dimensions, to assist in the development of welding procedures, and to aid in the generation of process control algorithms for automated applications. In this work, a three-dimensional (3-D), steady-state thermal model of the GMA welding process has been formulated for a moving coordinate framework and solved using the finite-element method. The model includes temperature-dependent material properties, a new finite-element formulation for the inclusion of latent heat of fusion, a Gaussian distribution of heat flux from the arc, plus the effects of mass convection into the weld pool from the melted filler wire. The influence of weld pool convection on the pool shape was approximated using anisotropically enhanced thermal conductivity for the liquid phase. Weld bead width and reinforcement height were predicted using a unique iterative technique developed for this purpose. In this paper, the numerical model is shown to be capable of predicting GMA weld dimensions for individual welds, including those with finger penetration. Also, good agreement is demonstrated between predicted weld dimensions and experimentally derived relations that describe the effects of process variables and their influence on average weld dimensions for bead-onplate GMA welds on steel plate.
110 citations
Journal Article•
TL;DR: In this paper, the authors investigated the effects of solid-state phase transformation on residual stresses and deformations in low carbon and medium carbon steels welded by the TIG arc welding process.
Abstract: The objective of this work was to investigate the effects of solid-state phase transformation on residual stresses and deformations in low carbon and medium carbon steels welded by the tungsten inert gas (TIG) arc weldingprocess. An uncoupled thermal-mechanical three-dimensional finite element model that took into account the solid-state phase transformation was developed. In this study, different continuous cooling transformation (CCT) diagrams were used to predict the fractions of martensite for the coarse-grained HAZ and the fine-grained HAZ, respectively. Effects of volume change due to austenite-martensite transformation on residual stress and distortions were studied. The analysis of low carbon steel revealed that the residual stress and deformation did not seem to be affected by phase transformation during cooling. However, for medium carbon steel, the residual stresses and deformation were significantly affected by low temperature phase transformation..
40 citations