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Development of efficient three-dimensional welding simulation approach for residual stress estimation in different welded joints
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering, Lightweight Structures.ORCID iD: 0000-0003-4180-4710
2012 (English)In: Journal of Strain Analysis for Engineering Design, ISSN 0309-3247, Vol. 47, no 8, 539-552 p.Article in journal (Refereed) Published
Abstract [en]

Based on the available welding simulation approaches found in the literature, an alternative and simplified welding simulation approach is developed, called rapid dumping. It is a sequential thermomechanical approach, which makes use of the moving heat source in thermal analysis and the block-dumping approach in mechanical analysis for prediction of welding residual stresses in three dimensions. It is first developed for longitudinal stiffener joint and then validated by applying on a butt-welded, T-fillet, and multipass tube-flange joints. The temperature-dependent material properties were obtained using JMat Pro software, a java-based material property simulation software. The material properties were validated with experimentally determined material properties found in the literature. The predicted residual stresses were validated by X-ray diffraction measurements on the longitudinal stiffener fillet-welded joint. Using the rapid-dumping approach, the residual stresses obtained at the weld toe were in qualitatively good agreement with the measured residual stresses. The rapid-dumping approach showed to capture the effects of moving heat source and weld start/stop location. In addition, it has reduced the computational time significantly with a preserved accuracy of the estimated welding residual stresses.

Place, publisher, year, edition, pages
2012. Vol. 47, no 8, 539-552 p.
Keyword [en]
Finite element method, welding simulation, X-ray diffraction and residual stresses
National Category
Metallurgy and Metallic Materials
URN: urn:nbn:se:kth:diva-107623DOI: 10.1177/0309324712463866ISI: 000311037100001ScopusID: 2-s2.0-84872004659OAI: diva2:576970
EU, European Research Council

QC 20121214

Available from: 2012-12-14 Created: 2012-12-14 Last updated: 2015-05-29Bibliographically approved
In thesis
1. Computational weld mechanics: Towards simplified and cost effective FE simulations
Open this publication in new window or tab >>Computational weld mechanics: Towards simplified and cost effective FE simulations
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

It is the demand of the world’s ever increasing energy crisis to reduce fuel consumption wherever possible. One way of meeting this demand is by reducing the weight of a structure by replacing thick plates of low strength steel with thin plates of high strength steel in the structure. Fusion welding process is extensively used in the manufacturing industry, however, despite many advantages different problems such as weld defects, residual stresses and permanent distortions are associated with this process.

Finite element (FE) method has proved itself as an alternative and acceptable tool for prediction of welding residual stresses and distortions. However, the highly nonlinear and transient nature of the welding process makes the FE simulation computationally intensive and complex. Thus, simplified and efficient welding simulations are required so that they can be applied to industrial scale problems.

In this research work an alternative FE simulation approach for the assessment of welding residual stresses, called rapid dumping is developed. This approach proved to be efficient and predicted the residual stress with acceptable accuracy for different small scale welded joints. This approach was further implemented on a large scale welded structures along with other available approaches. It was found that the computational time involved in the welding simulations for large structures using rapid dumping approach can be reduced but at the cost of accuracy of the results.

Furthermore, influence of thermo-mechanical material properties of different steel grades (S355-S960) on welding residual stresses and angular distortion in T-fillet joints is investigated. It is observed that for assessment of residual stresses, except yield stress, all of the thermo-mechanical properties can be considered as constant. For the prediction of angular distortions with acceptable accuracy, heat capacity, yield stress and thermal expansion should be employed as temperature dependent in the welding simulations.

Finally, the influence of two different LTT (Low Transformation Temperature) weld filler material on residual stress state and fatigue strength was investigated. It was observed that a reduction in tensile residual stresses at the weld toe of the joint was observed. Furthermore, at higher R-ratio no significant increase in the fatigue strength was observed . However, at low R-ratio significant  increase in fatigue strength was observed.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. xii, 26 p.
TRITA-AVE, ISSN 1651-7660 ; 2015:32
National Category
Manufacturing, Surface and Joining Technology Vehicle Engineering
Research subject
Vehicle and Maritime Engineering
urn:nbn:se:kth:diva-168174 (URN)978-91-7595-626-8 (ISBN)
Public defence
2015-06-15, D3, Lindstedtsvägen 5, KTH, Stockholm, 09:00 (English)

QC 20150529

Available from: 2015-05-29 Created: 2015-05-27 Last updated: 2015-05-29Bibliographically approved

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Bhatti, Ayjwat A.Barsoum, Zuheir
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