Abstract
Welding of nickel-based alloys is increasingly used in the industry to manufacture many important components of the marine industries, chemical processing, etc. In this study, a 3D thermomechanical finite element (FE) analysis is employed to evaluate residual stresses and deformations caused by the tungsten inert gas (TIG) welding of Monel 400 (Nickel-Copper alloy) plates. The FE results related to the residual stresses and deformations have been verified by using the hole-drilling stress measurement and common dimensional measurement tools, respectively. Residual stresses analyzed by the FE simulation are then compared with those obtained from ultrasonic stress measurement. The ultrasonic stress measurement is based on acoustoelasticity law, which presents the relation between the acoustic waves and the stress of material. The ultrasonic stress measurement is carried out by using longitudinal critically refracted (LCR) waves which are longitudinal ultrasonic waves propagated parallel to the surface inside the tested material. Two welded plates are experimentally prepared (with and without using clamp) to investigate the clamping effect on the welding residual stress and deformations. By utilizing the FE analysis along with the LCR method, the distribution of longitudinal residual stress could be achieved. It has been concluded that the applied methodologies are enough accurate to distinguish the clamping effect on the welding residual stresses and deformations of Monel plates.
Highlights
IntroductionMonel is a trademark for a series of nickel alloys, composed of nickel (up to 67%) and copper, with some iron and other trace elements (Table 1)
The longitudinal residual stresses are analyzed by finite element (FE) welding simulation, measured by ultrasonic method and verified by hole-drilling measurement
It should be noticed that the longitudinal critically refracted (LCR) ultrasonic method measures average of stresses in the 2 mm depth the average of stresses in 0-2 mm from the surface are considered in obtaining the FE simulation results
Summary
Monel is a trademark for a series of nickel alloys, composed of nickel (up to 67%) and copper, with some iron and other trace elements (Table 1). MONEL alloy 400 is a solid-solution alloy that can be hardened only by cold working. It has considerable strength and toughness over a wide temperature range and exceptional resistance to many corrosive environments [1]. Monel 400 is widely used in many industries, especially marine and chemical processing. Some of common applications include valves and pumps, marine fixtures and fasteners, springs, chemical processing equipment, gasoline and fresh water tanks, crude petroleum stills, process vessels and piping, boiler feed-water heaters and deaerating heaters [1]
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