Abstract
In the present study, a finite element-based 3D mesh model is used to simulate the effect of welding processes on the temperature distribution, residual stress and distortion in 11-mm-thick 2.25Cr-1Mo steel weld joints. Tungsten inert gas (TIG) and activated-TIG (A-TIG) welding processes were employed for the fabrication of weld joints. Austenite-to-bainite phase transformation is taken into account in the numerical analysis. The heat input fitting tool has been used to calibrate the heat source by matching the simulated weld bead with that of the actual weld bead. Peak temperature was higher at the weld center for A-TIG weld joint, and the weld joint exhibited a sharp temperature gradient at the weld interface. There was good agreement between the predicted and measured thermal cycles. A-TIG and multipass-TIG (MP-TIG) weld joints exhibited similar longitudinal residual stresses in heat affected zone with a difference of 50 MPa. Moreover, A-TIG weld joint fabricated by double-side welding technique employing two passes exhibited reduced distortion than MP-TIG weld joints. A higher magnitude of distortion was in MP-TIG weld joint which was attributed to more weld metal volume caused by more number of weld passes required to fill the V-groove. There was good agreement between the predicted and measured residual stress and distortion values.
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