Abstract
Transient distortion of thin plate in the welding process usually has a complicated mode and large magnitude. Quantitative measurement and prediction of full-field distortion are challenging and rarely reported up to now. In this study, the out-of-plane distortion of a thin plate during the Tungsten Inert Gas (TIG) welding process was measured using the digital image correlation (DIC) method. A simulation model based on thermal elastic–plastic finite element method (FEM) and DIC measured geometric imperfection were developed for accurate prediction of the transient welding distortion. The numerical results and experimental data agreed very well in both out-of-plane deformation modes and magnitudes of the plate at different stages of welding. The maximum out-of-plane distortion was larger than 4 mm during welding which can cause instability of arc length and heat input. The distance change between welding torch and plate surface was investigated under different initial deflections of the plate before welding. The plate with flat geometry shows the minimum transient and final gap change. In addition, the relationship between heat input and welding distortion was clarified through a series of numerical analyses. Optimization of welding heat input can be performed based on numerical results to avoid excessive welding distortion.
Highlights
Fusion welding is widely used in the manufacturing industry, such as automobile and shipbuilding, to join metallic parts
To simulate the welding-induced buckling distortion, the modelling procedure was presented by Yang et al [24], the material model was discussed by Bhatti et al [25], and the effect of initial deflection of thin plates was investigated by Huang et al [26]
The developed 3D thermal–mechanical finite element method (FEM) method can accurately predict the transient distortion in welding by considering the measured geometrical imperfection
Summary
Fusion welding is widely used in the manufacturing industry, such as automobile and shipbuilding, to join metallic parts. To simulate the welding-induced buckling distortion, the modelling procedure was presented by Yang et al [24], the material model was discussed by Bhatti et al [25], and the effect of initial deflection of thin plates was investigated by Huang et al [26]. The out-of-plane distortion of a Tungsten Inert Gas (TIG) welded bead-on-plate was investigated by both in-situ digital image correlation (DIC) measurement and 3D thermo-mechanical simulation of transient distortion in welding needs to be validated by the in‐situ measured information, the development of advanced measuring techniques for the full‐field welding deformation is especially important. To clarify numerical model so that thethe deformation mode and magnitude in the time history canon beheat accurately possible ways to minimize out‐of‐plane distortion in welding, parametric studies input simulated. Computation offers an accurate way of transient welding distortion prediction and control
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