Abstract
This article reports on a numerical and experimental investigation to understand and improve computer methods in application of the Goldak model for predicting thermal distribution in submerged arc welding (SAW) of APIX65 pipeline steel. Accurate prediction of the thermal cycle and residual stresses will enable control of the fusion zone geometry, microstructure, and mechanical properties of the SAW joint. In this study, a new Goldak heat source distribution model for SAW is presented first. Both 2D and 3D finite element models are developed using the solution of heat transfer equations in ABAQUS Standard implicit. The obtained results proved that the 2D axi-symmetric model can be effectively employed to simulate the thermal cycles and the welding residual stresses for the test steel. As compared to the 3D analysis, the 2D model significantly reduced the time and cost of the FE computation. The numerical accuracy of the predicted fusion zone geometry is compared to the experimentally obtained values for bead-on-plate welds. The predictions given by the present model were found to be in good agreement with experimental measurements.
Highlights
Because of its high quality and reliability, submerged arc welding (SAW) is employed extensively in industry to join metals for the manufacture of energy transportation pipes applied for different applications [1,2,3]
The main objective of this research is to develop a FEA model that is capable of predicting the SAW thermal cycle and residual stress with higher accuracy compare to the available results in literature
The results show an almost similar trend to that of transverse stresses though the magnitude of the longitudinal stresses are about twice the maximum value of transverse residual stresses
Summary
Because of its high quality and reliability, submerged arc welding (SAW) is employed extensively in industry to join metals for the manufacture of energy transportation pipes applied for different applications [1,2,3]. The service performance of SAW joints is dependent on the fusion zone microstructure, which itself is dependent on the weld thermal cycle and alloying elements [4]. It is challenging and costly to quantify the thermal cycles and temperature fields by pure experimental studies. FEA analysis can be employed to effectively predict the welding temperature field, cooling rate, microstructure and residual stresses. A moving arc of sufficient energy input is incident upon the work-piece surface at a constant welding speed. A fraction of the incident energy is absorbed by the work-piece leading to the formation of a fusion zone. As the electrode passes over the work-piece, the melt pool extends along the scanning direction and solidifies soon after the electrode and contact tip moves away
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