Abstract
Finite element (FE) analysis of welding residual stress and deformation is one of the essential stages in the manufacturing process of mechanical structures and parts. It aids in reducing the production cost, minimizing errors, and optimizing the manufactured component. This paper presents a numerical prediction of residual stress and deformation induced by two-pass TIG welding of Al 2219 plates. The FE model was developed using ABAQUS and FORTRAN packages, Goldak’s heat source model was implemented by coding the nonuniform distributed flux (DFLUX) in user subroutine to represent the ellipsoidal moving weld torch, having front and rear power density distribution. Radiation and convection heat losses were taken into account. The mechanical boundary condition was applied to prevent the model from rotation and displacement in all directions while allowing material deformation. The FE model was experimentally validated and the compared results show good agreement with average variations of 18.8% and 17.4% in residual stresses and deformation, respectively.
Highlights
Tungsten Inert Gas (TIG) welding is a commonly used manufacturing process by the automobile, aviation, and aerospace manufacturing industries, etc. for joining non-ferrous metals [1] such as aluminum and magnesium
An inter-pass temperature of 86.76 ◦ C was determined between pass 1 and 2, but an inter-pass cooling effect was not simulated in this work
The consequences of non-uniform cooling due to convection and radiation results in a rapid drop of the peak temperature as the heat source passes a particular position with constant speed, which in turns leads to residual stress formation
Summary
Tungsten Inert Gas (TIG) welding is a commonly used manufacturing process by the automobile, aviation, and aerospace manufacturing industries, etc. for joining non-ferrous metals [1] such as aluminum and magnesium. The induced thermal cycle from the TIG welding results in high residual stresses and deformation on the weld metal and heat-affected zone (HAZ), which adversely affects the mechanical performance of the components. They require a significant consideration during design and manufacture of structural elements. There are various factors and parameters influencing the magnitude and distribution of residual stresses and deformation during welding. They include the type of weld, number of weld-passes, sequence and direction of welding stitches, fixing method, etc
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