Abstract
An analytical model is proposed to rapidly capture the thermal and residual stresses values induced by the hybrid metal extrusion and bonding (HYB) process on dissimilar-metal butt-welded joints. The power input for two welding velocities is first assessed using a thermal–mechanical model solved by a heat generation routine written in MATLAB code. Subsequently, the obtained temperature history is used as input to solve the equilibrium and compatibility equations formulated to calculate the thermal and residual stresses. To verify the soundness of the analytical approach, a Finite Element numerical model of the entire process is carried out and results are compared with those coming from the proposed rapid method. It is found that the degree of accuracy reached by the analytical model is excellent, especially considering the tremendous time reduction when compared to that characterizing the standard numerical approach.
Highlights
Metal structures subjected to welding processes are characterized by residual stresses that are a consequence of heating and cooling cycles occurring in the joint and in the parent material
In his work, Deng [11] used a coupled thermal, metallurgical, and mechanical 3D finite element model to investigate the effects of solid-state phase transformation on welding residual stress and distortion in low carbon and medium carbon steels, revealing that the final residual stress and distortion in low carbon steel did not seem influenced by the solid-state phase transformation, while for the medium carbon steel, the final residual stresses and distortions appeared to be affected by the martensitic transformation
The present work is aimed at filling this gap by extending the analytical model proposed by Ferro [21] to dissimilar aluminum–steel butt-welded joints produced via hybrid metal extrusion and bonding (HYB)
Summary
Metal structures subjected to welding processes are characterized by residual stresses that are a consequence of heating and cooling cycles occurring in the joint and in the parent material. In the case of butt-welded plates, during the heating phase, compression stresses arise near the joint along the weld line This happens because the thermal expansion of the hot area is constrained by the mass of the parent material that remains cold. Chen et al [12] developed a threedimensional finite element model to investigate the thermal history and thermomechanical process of friction stir (FS) butt-welded AA6061-T6 plates They investigated the evolution of longitudinal, transversal, and through-thickness stress and used X-ray diffraction to validate their results. The present work is aimed at filling this gap by extending the analytical model proposed by Ferro [21] to dissimilar aluminum–steel butt-welded joints produced via HYB. A 3D finite element model was developed that uses a doubleand ellipsoid volume function with Gaussian power distribution to simulate the Materials
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