Finite Element Analysis to Determine Residual Stress in Electron Beam Welding of CuCrZr alloy Plates and Experimental Validation

Abstract

The study on determining residual stresses in welding process through finite element (FE) analysis could receive much attention in the last decades. The prediction of residual stresses and temperature distribution is important for many industries, as it can ensure more efficient mechanical design. Electron beam welding (EBW) of copper chromium zirconium (CuCrZr) alloy was carried out in the bead-on-plate configuration. The temperature fields and stress distributions in the welded joint during the welding process were numerically simulated and experimentally verified. 3D finite element models were developed using the solution of heat transfer equations in Ansys mechanical APDL. Here, conical heat source was used for simulation. The temperature distribution was obtained, and stress analysis was carried out with the developed model using the temperature dependent material properties for CuCrZr.The temperature distribution was symmetric along the weld center, and the thermal stress also appeared to be in symmetric distribution. The predicted results were verified through real experiments, and a good agreement between them was achieved.