Abstract
A thermo-mechanical analysis of multi-pass GTA welding of 6mm thick Grade 91 steel plate was carried out using three different models which include a 2D model, a 3D coarse meshed model and a 3D fine meshed model. Predicted thermal cycles, residual stresses and distortion were validated using experimental tools. Effect of preheat employed between weld passes on distortion was simulated and also experimentally validated. Good correlation was obtained between experimental results and those predicted from the simulation for 3D fine meshed model. Distortion analysis carried out using the above model considering phase transformation effect and employing large distortion theory predicted distortion values very close to that of the actual values. For simulating preheat, a circular disc shaped heat source and for simulating GTA welding, a double ellipsoid heat source model were employed. Experimental and FEM results show that preheating up to 200°C reduced the distortion of Grade 91 steel plate considerably during multi-pass welding.
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