Abstract
Some fundamental principles and advanced applications of thermo-mechanical modelling techniques used for industrial welding processes are described. The paper covers a range of modelling procedures comprising welding simulation and residual stress analysis of multi-pass, thick-walled ferritic steel pipes; welding simulation and distortion analysis of nickel-based superalloy thin plates; and inertia friction welding of dual alloy drive shafts. A number of pertinent mechanical and metallurgical concepts are discussed, including material behaviour models and material properties, microstructural evolution, solid state phase transformation and post-weld heat treatment. The paper emphasises the general methodologies of thermal modelling procedures and their role in the holistic process of the life assessment and design improvement of power plant piping systems and aeroengine casings and shaft components, operating under high temperature creep and fatigue service conditions.
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