Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding.

Woo-Jae Seong

doi:10.3390/ma12091435

Abstract

Multi-layer welding involves the process of stacking many beads, so it requires much time and effort to predict the deformation through experimentation or numerical analysis. In this study, a systematic method for predicting transverse angular distortion in multi-layer butt welding has been proposed. First, the database was established through bead-on-plate welding experiments, which consisted of the relationship between welding conditions, the bead geometry, the material thickness, and the angular distortion. Then, when the arbitrary welding conditions and the shape of the butt joint were input, the method calculated the angular distortion per pass using the geometric principle and the database. The obtained prediction curves were verified with the V-groove welding experimental results. In addition, the characteristics of angular distortion in multi-layer butt welding were discussed. It was found that the angular distortion curve is a function of the number of passes and groove geometry. This algorithm is based on a numerical approach that saves computational time using databases and geometry, so it is suitable for industrial applications.

Highlights

In industrial manufacturing processes, welding is used to assemble at least two members into a designed structure
The results revealed that welding distortion depends on H/t2 with the same material
A method of predicting angular distortion in multi-layer welding has been developed using the relationship between welding conditions and geometrical information

Summary

Introduction

In industrial manufacturing processes, welding is used to assemble at least two members into a designed structure. Of many types of welding processes, arc welding provides high thermal energy to fuse metals to localized areas. For the consumable electrode method, the molten wire is transferred to the base metal and cooled, while the base material undergoes both the heating and cooling process by heat conduction from the molten wire. In the case of the base material, the amount of compressive plastic strain generated during heating is larger than that of tensile plastic strain during cooling, leading to permanent deformation. The surrounding region has compressive residual stress [1,2,3,4,5]. It has been well known that tensile residual stress affects brittle fracture, fatigue life, stress corrosion cracking, weld cracks, and buckling strength [6]

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