Welding Deformation Research Articles

Residual stress and deformation of welded T-joint between low carbon steel and stainless steel

The welded structures between carbon steel and stainless steel are widely used in many sectors such as pedestrian bridges, food industry, chemical industry, petroleum, and thermal power plants, … These composite structures take advantages of each material for different parts of structure. In the welded structures between carbon steel and stainless steel, the structure is made by T-joint that is the most common. The calculation of residual stress and welding strain of the T-joint between low-carbon and stainless steel materials is the basis to evaluate the working ability of this structure. In this study, the residual stress and welding deformation of the T-joint are determined by the imaginary force method. The double-sided weld of T-joint between low carbon steel and stainless steel is welded simultaneously by MIG welding process. The obtained results of residual stress and welding deformation in this case are compared with the case of single-sided weld so that we can find the difference between residual stress and welding deformation in two cases.

A new analytical model for predicting the welding deformation of large welded plates with equivalent moments

The efficient prediction of welding deformation is important for the deviation control of large welded structures. In this paper, an analytical model is proposed to predict the welding deformation of large aluminium alloy plates. The welding-induced equivalent moments are calculated based on the inherent strain of a small-scale welded plate. The large welded plate is regarded as a corner-supported plate subjected to the equivalent moments. The welding deformation of the large welded plate is analytically derived by using the reciprocal theorem of work, and is validated by the experimental data. The effect of heterogeneous weld properties and plate dimensions on the welding deformation is quantitatively discussed. The proposed model can facilitate the deformation prediction of large welded structures.

Impact Analysis of Welding Sequence to Reduce Weld Deformation in Aluminum Hulls

Aluminum hulls, which are preferred in the marine industry due to their durability, corrosion resistance, and lightweight properties, face serious challenges due to thermal deformation during welding. This study aims to predict and minimize transverse deformations due to welding sequences for a transverse model in the lower part of an aluminum hull. To predict deformations, heat source dimensions obtained from actual weld beads were used as simulation conditions, and various welding sequence conditions were simulated through the developed finite element method (FEM). The simulation results were compared with actual deformation measurements to verify their reliability, and the optimal welding sequence which minimized deformation was derived. The simulation results show that by changing the welding sequence conditions, the maximum displacement can be reduced from a maximum of 52.1% to a minimum of 39.1%, and the effective plastic strain can be reduced from a maximum of 19.6% to a minimum of 4.8%. These results show that adjusting the welding sequence conditions can significantly improve structural integrity by minimizing deformation. The results of this study suggest that the control of the welding sequence can be used to reduce the deformation of aluminum hulls and promote a more sustainable marine industry with improved quality.

Numerical investigation of welding deformation diminution for double shell structure using the layered inherent strain

Cyclotron is a key scientific tool and indispensable research platform for conducting cutting-edge research in nuclear equipment development as well as innovative applications of nuclear technology. The shell component has a double-layer thick-walled structure with intricate ribs and high-density, full-penetration welded joints. The mitigation of welding deformation is of profound significance to the performance of the cyclotron. The thick plate joint has many welding layers which will be divided into several steps to complete the backing, filler, and cap welding. The equivalent transverse and longitudinal plastic strains of different layers were extracted by the thermo-elastic-plastic method. The welding deformation generated by each layer of weld can be predicted by using the equivalent plastic strain, and the total distortion can be accumulated layer by layer. Numerical simulation and experimental studies were conducted on the welding deformation of the double shell specimen, and the welding sequence and design of the welding fixture were discussed in detail. The digital photogrammetry system was used to monitor the deformation state of the welded parts in real-time. The measured deformation was compared with the simulation results. Ultimately, the deformation of the specimen is controlled at 2.64 mm. The proposed method can flexibly evaluate the impact of each welding layer on welding deformation for multiple welds, which can provide technical guidance for cyclotron engineering manufacturing.

Mechanism clarification and mitigation measures of radial deformation induced by girth welding of thin-walled pipes

Girth welding is extensively utilized in connecting pipeline structures. Excessive welding deformation may result in a decrease in ultimate bearing capacity and fatigue life. This research explores the characteristics and underlying mechanics of radial deformation in thin-walled girth welded pipes and proposes mitigation measures. Initially, several 304 stainless steel pipes were joined utilizing four distinct welding procedures. Welding deformation and residual stress distribution were measured using a 3D coordinate measuring machine (CMM) and the Cos α X-ray diffraction (XRD) method, respectively. Subsequently, numerical models were developed to simulate the welding process and verify the accuracy of the fusion zone, residual stress field, and radial deformation in the models. The mechanism of radial deformation was further elucidated based on the inherent strain method. The results show that the direction of radial deformation relies substantially on the hoop plastic strain. Hoop tensile plastic strain corresponds to radial outward deformation, while hoop shrinkage plastic strain corresponds to radial inward deformation. In addition, the influence of axial constraint on the formation process and results of hoop plastic strain, as well as the effect of heating zone width on radial deformation, was studied. Through simulation outcomes, the research suggests employing a regulated heat source method to mitigate radial deformation, which could potentially reduce deformation by 92.8%, offering considerable advantages in deformation mitigation and welding efficiency augmentation.

Influence of welding sequences and boundary conditions on residual stress and residual deformation in DH36 steel T-joint fillet welds

This paper aims to investigate the influence of welding sequences and boundary conditions on welding-induced residual stress and residual deformation of DH36 steel T-joint fillet welds through experimental and numerical methods. A series of typical experiments of successive and simultaneous double-sided welding conditions are conducted to explore both the magnitude and distribution of temperature field, residual stress and residual deformation. Meanwhile, thermal elastic-plastic finite element analysis based on a double ellipsoidal heat source model is performed to investigate the heat transfer and deformation mechanism during the welding process. The influencing factors are further explored to determine and quantify the residual stress and residual deformation induced by different welding sequences and boundary conditions. There is generally well agreement between the experimental and numerical results in terms of temperature field, residual stress, residual deformation and molten pool morphology. The results show that the welding sequences have an important influence on the magnitude and distribution of residual stress and residual deformation. Continuous simultaneous double-sided welding can significantly reduce residual stress and residual deformation to obtain better-quality welds. Boundary conditions have a significant effect on the distribution and magnitude of residual deformation and little effects on residual stress. Tightening the ends of the flange plate with bolts during the welding process can significantly reduce the deformation.

Current status and application of welding automation technology for bridge steel structure

Abstract In bridge construction, welding automation technology has become an indispensable and important technical means for developing related industries. The paper mainly introduces the current status of welding automation technology in bridge steel structures, elaborates on its existing technology from the control of welding deformation, U-frame welding process, robot welding technology, etc., and gives full play to the positive role of advanced steel structure welding automation technology, and forms a good working mode and technical system. The difficulties in welding are analyzed, which plays a role in promoting the development of welding automation technology for bridge steel structures.

Fatigue strength of welded joints of marine aluminum alloy extrusion stiffened plate considering welding effects

Due to the low stiffness of thin-plate welded structure, the influence of welding effect on fatigue evaluation of thin-plate welded structure cannot be ignored. Extruded stiffened plates are tried to be used in hull structures because of their excellent forming technology, which can greatly reduce welding deformation and defects. By carrying out fatigue tests of extruded reinforced welded joints and traditional T-shaped welded joints, the S-N curves of typical T-welded joints are obtained and compared. Furthermore, the residual stress and welding deformation of stiffened model and traditional T-model are predicted by numerical simulation. The welding effects are introduced into the calculation of hot spot stress as the initial value, and the hot spot stress class curves of extruded reinforced welded joints and traditional T-welded joints are renewed. Compared with traditional welded joints, extruded welded joints are less affected by residual stress and welding deformation. The study revealed that residual stress and welding deformation exhibited a higher sensitivity to the fatigue strength of traditional thin-plate welded structures.

Prediction of Welding Deformation Using the Thermal Elastic-Plastic Finite Element Method by Considering Welding Interpass Temperature.

In this study, we propose a method for predicting welding deformation caused by multi-pass welding using the thermal elastic-plastic finite element method (TEP-FEM) by considering the interpass temperature. This method increases the interpass temperature, which has not been considered in the existing TEP-FEM, from 200 °C to 1000 °C, and simultaneously performs thermal and mechanical analyses. In addition, this method can also evaluate temperature history and the time it takes to weld. By predicting the welding deformation using this method, angular distortion prediction was reduced from 16.75 mm to 10.9 mm compared to the case where the interpass temperature was cooled to room temperature. Additionally, the deformation error was significantly reduced from 6.14% to 2.92% compared to that of the strain as directed boundary method used in a previous study. Additionally, our research demonstrated that interpass temperatures above 800 °C can result in increased deformation errors. In conclusion, it is essential to select an appropriate temperature to minimize deformation error.

Design and Performance Study of Carbon Fiber-Reinforced Polymer Connection Structures with Surface Treatment on Aluminum Alloy (6061)

The existing connection methods for aluminum alloy profiles primarily include adhesive bonding and mechanical connections, with metal welding being widely employed. However, metal welding connections exhibit issues such as low joint strength, significant welding deformation, susceptibility to surface oxidation, poor welding surface quality, and challenges in achieving thin-walled metal structures. This paper presents a novel aluminum alloy connection structure that utilizes carbon fiber-reinforced polymer (CFRP) composites to replace welding for connecting aluminum alloy profiles. This innovative aluminum alloy composite connection structure not only enhances connection strength but also addresses the difficulties associated with metal welding. Research indicates that the optimal width of the CFRP structure in the connector is 60 mm, and with synergistic treatment of the aluminum alloy surface, the connection enhancement effect is optimal. Under these conditions, the tensile load can reach 58.71 kN and the bending load can reach 14.33 kN, which are 375.38% and 380.87% higher than those of welded aluminum alloy connections, respectively. The mass-specific strength increases by 106.27% and 134.42%, respectively. Simulations of this connection structure in components demonstrate that it improves strength by 73.99% and mass-specific strength by 71.95% compared to pure metal welded connections. Using ABAQUS 2023 software for simulation and calculation, the difference between the simulation and experimental results is within 5%, verifying the feasibility of the designed structure. This study provides new insights and a theoretical foundation for the development and application of hybrid connection methods involving metal and fiber-reinforced composites.

Enhancing strength and toughness of GNS/Al nanocomposites via a hybridization strategy

Good strength-ductility balance in graphene nanosheet (GNS)-reinforced aluminum nanocomposites can be achieved through tailorable and facile agglomeration control. Our previous study showed that pre-modulating the Al powder morphology by adding hard silicon carbide nanoparticles (SiCnp) during the two-step ball milling process effectively promotes the uniform dispersion of GNSs. However, excess SiCnp content causes SiCnp aggregate and premature cracking of composites. Here, GNS-reinforced aluminum nanocomposites with different SiCnp content (0.3–1.5 vol%) were prepared, and the optimal SiCnp-to-GNS ratio was determined after optimizing the SiCnp content in a pre-studied composite preparation process. The effect of SiCnp on the microstructure and mechanical properties of the composites was systematically investigated. The cold welding deformation of Al flakes increased with the SiCnp content. Nonetheless, inadequate or excessive SiC content caused insufficient lamination or excessive cold-weld stacking of Al flakes, respectively. Al-0.9vol.%SiCnp powders possessed the highest specific surface area which resulted in high homogeneous dispersion of 3.0 vol% GNS during the second ball-milling stage. Consequently, the resulting hybrid reinforced (GNS + SiCnp)/Al composites showed simultaneous improvement in strength and plasticity, unlike Al-3.0vol.%GNS composites. This showed that introducing hard nanoparticles (i.e., the hybridization strategy) is a promising method to simultaneously enhance strength and plasticity of aluminum nanocomposites.

The influence of hydrogen content on the Zr-4 alloy diffusion bonding joint: From experiments to molecular dynamics simulations

Bonding the Zr-4 alloy in the high temperature can lead to many problems, for example grain coarsening and large welding deformation resulting from high residual stresses. Hydrogenation is an effective approach to decrease the bonding temperature. In the present research, the influence of hydrogen contents on the microstructure evolution and shear strength of Zr-4 alloy joints were studied. The number of interface voids markedly decreased with increasing hydrogen content at 650 °C. A sound joint was obtained at the hydrogen content of 0.2 wt% hydrogen. This achieved joint had a shear strength of 244 MPa, and the fracture mode of the joint presented the brittle/ductile mixed mode. With the increase of hydrogen content, the flow stress of the hydrogenated Zr-4 alloy decreased due to the decomposition of zirconium hydrides. The plasticity of the joint enhanced with increasing hydrogen content in the view of electron backscatter diffraction (EBSD) results, and the kernel average misorientation increased from 0.11° to 0.77°. In addition, the diffusion behavior and diffusion coefficient of the Zr atoms were investigated by molecular dynamics simulation. The calculation results showed that hydrogen enhanced the diffusivity of the Zr atoms, and the diffusion coefficient of the Zr atoms accordingly increased by four orders of magnitude. The addition of hydrogen influenced the directly diffusion bonding process through two aspects: improvement of plasticity and enhancement of diffusion ability.

A Study on the Effects of Welding Deformation According to Weld Sequence in Overlay-Welded Structures

In this study, thermal elasto-plastic finite element analysis was conducted to derive the optimal welding sequence to minimize overlay welding deformation on the water wall panels of an SRF (solid refuse fuel) boiler. The water wall panels of an SRF boiler are exposed to high temperatures and corrosive environments, making overlay welding essential. However, because the length of the water wall panels and tubes exceeds 7 m, significant deformation occurs after overlay welding. Additionally, due to the large size of the water wall panels, full-size thermal elasto-plastic analysis requires huge computational costs. Therefore, in this study, the effects of welding sequence on overlay welding deformation were first investigated for a reduced model to derive the optimal welding sequence. Subsequently, an analysis model for the full-size pipe panels was established to compare and analyze the conventional welding sequence with the optimal welding sequence, thereby verifying the validity of the study. According to the welding sequence derived from the reduced model, welding deformation in the full-size model was significantly reduced compared to the conventional sequence. This reduction in deformation was discussed by analyzing the deformation behavior of the structure at each stage of the overlay welding process.

Numerical Simulation Study on Welding Process of Upper Frame of Hydropower Unit

To optimize the welding process of the upper frame of the hydropower unit, a thermal elastic–plastic (TEP) finite element model of the typical T-joint of the upper frame was established, and the effectiveness and accuracy of the model were verified by welding tests. The effect of welding speed and interlayer cooling time on welding residual stress and deformation was analyzed, and a welding process in line with the requirements was obtained. Based on the results of the TEP calculation, the inherent strain was obtained, and the inherent strain method (ISM) was used to predict the overall deformation of the upper frame under three welding sequence schemes, and the optimal welding sequence was obtained.

Research on Predicting Welding Deformation in Automated Laser Welding Processes with an Enhanced DEWOA-BP Algorithm

Research on Predicting Welding Deformation in Automated Laser Welding Processes with an Enhanced DEWOA-BP Algorithm

Research on welding simulation for vacuum chamber test specimens

The vacuum chamber is an important component of nuclear fusion devices, and the deformation control of the welding process is relatively strict. In this paper, the isothermal multi-level cyclic loading tests have been conducted to explore a nonlinear mixed hardening mode, which can be used as the material input for the welding simulation. Then, welding simulation has been performed for test specimens of the vacuum chamber, and the deformation of test specimens has been obtained under different welding paths. After the first welding simulation is completed, the clamp and limiting plates have been designed based on the deformation of the test specimens. The welding simulation has been performed again with the clamp and limiting plates, in order to evaluate the rationality of the welding process and the design for the clamp and limiting plates. Finally, according to the determined welding process and design for the clamp and limiting plates, welding tests have been conducted, and the welding deformation has been measured. It is found that the difference between the measurement values of the tests and the simulation results is small, which implies that the welding simulation is reasonable.

Omnidirectional simulation analysis of thermo-mechanical coupling mechanism in inertia friction welding of Ni-based superalloy

The coupling between heat and pressure is the kernel of inertia friction welding (IFW) and is still not fully understood. A novel 3D fully coupled finite element model based on a plastic friction pair was developed to simulate the IFW process of a Ni-based superalloy and reveal the omnidirectional thermo-mechanical coupling mechanism of the friction interface. The numerical model successfully simulated the deceleration, deformation processes, and peak torsional moments in IFW and captured the evolution of temperature, contact pressure, and stress. The simulated results were validated through measured thermal history, optical macrography, and axial shortening. The results indicated that interfacial friction heat was the primary heat source, and plastic deformation energy only accounted for 4% of the total. The increase in initial rotational speed and friction pressure elevated the peak temperature, reaching a maximum of 1525.5 K at an initial rotational speed of 2000 r/min and friction pressure of 400 MPa. The interface heat generation could form an axial temperature gradient exceeding 320 K/mm. The radial inhomogeneities of heat generation and temperature were manifested in a concentric ring distribution with maximum heat flux and temperature ranging from 2/5 to 2/3 radius. The radial inhomogeneities were caused by increasing linear velocity along the radius and an opposite distribution of contact pressure, which could reach 1.7 times the set pressure at the center. The circumferential inhomogeneity of thermo-mechanical distribution during rotary friction welding was revealed for the first time, benefiting from the 3D model. The deflection and transformation of distribution in contact pressure and Mises stress were indicators of plastic deformation and transition of quasi-steady state welding. The critical Mises stress was 0.5 times the friction pressure in this study. The presented modeling provides a reliable insight into the thermo-mechanical coupling mechanism of IFW and lays a solid foundation for predicting the microstructures and mechanical properties of inertia friction welded joints.

Fatigue Life and Crack Initiation of K and N Type Jacket Structure Using 3D Fatigue FE Analysis

Jacket structures are widely used as foundation structures for offshore wind energy. The jacket structure as a truss shape structure is not deformed easily and has the advantage of keeping the structure stable under wind load. The offshore jacket structures are subjected to unstable repetitive loads such as wind, and wave loads in the deep sea. These harsh environments lead to the deterioration of material performance and fatigue failure with cracks in the structure. It is crucial to locate fatigue cracks since they might compromise a structure's overall stability.In this study, fatigue life and crack initiation for different braced jacket structures were investigated. First, 3D non-steady heat conduction analysis and thermal elastic-plastic analysis were performed to reproduce the initial state of the weld joint in the jacket structure. The heat history obtained from the 3D non-steady heat conduction analysis was enforced as an input in thermal elastic-plastic analysis to calculate welding deformation and residual stress. Next, the fatigue FE analysis of the jacket welding structure was carried out using the residual stress and welding deformation as initial values along with the external cyclic loadings. The 3D fatigue FE analysis employed cyclic hysteresis constitutive equations and fatigue damage theory to calculate the fatigue life and crack initiation. The 3D fatigue FE results were compared with the S-N curve by European code 3 and the hot spot stress (HSS) method. The results show that the 3D fatigue FE method effectively calculates the fatigue life and finds crack initiation.

Effect of Welding Gap of Thin Plate Butt Welds on Inherent Strain and Welding Deformation of a Large Complex Box Structure.

In this study, an effective numerical model was developed for the calculation of the deformation of laser-welded 3 mm 304L stainless steel plates with different gaps (0.2 mm, 0.5 mm, and 1.0 mm). The welding deformation would become larger when the welding gaps increased, and the largest deformation values along the Z direction, of 4 mm, were produced when the gap value was 1.0 mm. A larger plastic strain region was generated in the location near the weld seam, since higher plastic deformation had occurred. In addition, the tensile stress model was also applied at the plastic strain zone and demonstrated that a larger welding gap led to a wider residual stress area. Based on the above results, inherent deformations for butt and corner joints were calculated according to inherent strain theory, and the welding formation for the complex structure was calculated with different gaps. The numerical results demonstrated that a larger deformation was also produced with a larger welding gap and that it could reach the highest value of 10.1 mm. This proves that a smaller welding gap should be adopted during the laser welding of complex structures to avoid excessive welding deformation.

Study of multi-pass laser welding deformation of bipolar plates by experiments and simulations

Study of multi-pass laser welding deformation of bipolar plates by experiments and simulations