Abstract
Welding process with trailing heat sink for 2 mm mild steel plates has been analyzed to estimate distortion and residual stresses using a finite element modeling software Sysweld. The material properties used for the analysis are both temperature dependent and phase dependent. A transient thermal analysis is carried out using Goldak double ellipsoidal heat source model and heat sink as Gaussian model with negative heat flux. The finite element analysis (FEA) is conducted by considering the material properties of all phases of steel as well as without phase transformation i.e. by considering properties of only ferrite phase. Temperature distribution, distortion and residual stresses are calculated and compared for four cases: without phase without cooling, without phase with cooling, with phase without cooling and with phase with cooling. It is found that FEA without phase transformation effects overestimates the residual stresses in the fusion zone (FZ) and heat affected zone (HAZ). It is also found that a trailing heat sink reduces transverse compressive residual stresses thus minimizing the possibilities of buckling.
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