Three dimensional modeling weld solidification cracks in multipass welding

This paper utilizes element birth and death finite element technique to control the process of filling metal step by step during multipass welding process. The dynamic thermal distributions and strain evolutions are simulated in 10 mm SUS310 stainless steel in multipass welding after taking into consideration of the fluid flow in the weld pool, the latent heat, taking into account the effect of the deformation in weld pool, change of initial temperature and solidification shrinkage. At the same time, the driving forces to weld solidification cracks of each weld pass are obtained successfully according to simulated thermal cycle (temperature against time) and mechanical strain cycle (mechanical strain against time). The results show the patterns of distribution of the driving force are similar to those of surface fusion welding. The driving force of first weld pass is larger than following weld passes and the driving force decreases gradually in company with welding processing. Sequent welding processes affect the mechanical strain distributions of previous weld pass, of which the tensile mechanical strain changes to compressive strain. In addition, the driving forces are analyzed and weld solidification cracks are predicted during multipass welding. The predicted results agree well with the experiments. Therefore, the simulated results in this study provide the foundation for predicting weld solidification cracking in actual weldment.     

A validated thermal model of bead-on-plate welding

In this paper, finite element model is used to carry out thermal analysis of bead-on-plate welding. The model followed the proposed five step strategies which were then built into a model to obtain temperature history at the positions of thermocouples. Temperature field was also evaluated by comparing predicted weld bead with the actual weld bead. Using these proposed strategies, well matched temperature histories and temperature field have been obtained.     

宽幅钢箱梁环焊缝焊接顺序优化研究

基于热弹塑性有限元法,采用ANSYS软件建立了网格疏密过渡的单箱五室钢箱梁壳单元模型;结合高效的分段移动热源,实现了对大型复杂长焊缝结构焊接全过程的数值模拟,并定性对比了宽幅钢箱梁在不同的环焊缝焊接顺序下顶板和底板的变形情况.分析结果表明:腹板焊缝的焊接顺序对竖向最大变形值(绝对值)的影响不大,其值主要取决于顶板和底板...     

Modeling of the thermal fluid flow and keyhole shape in stationary plasma arc welding

A three dimensional transient model has been developed to investigate the fluid flow and heat transfer in the weld pool with a dynamic-variation keyhole during stationary plasma arc welding (PAW). The level set method is used to track the moving boundary of the keyhole, and the evolution of both keyhole and weld pool in stationary keyhole PAW process are quantitatively analyzed. The thermal fluid flow of the molten metal surrounding the keyhole inside the weld pool is numerically simulated, and its effect on the keyhole shape is considered. The establishing time of an open keyhole is calculated for the stationary plasma arc welding of stainless steel plates with thickness 6 mm. The stationary keyhole PAW experiments are conducted to measure the keyhole shape, the fusion zone, and the establishment time of the keyhole. The predicted results, such as the keyhole length and width at bottom-side, the weld width at top- and bottom-side, and the establishment time of the keyhole, are in agreement with the experimental measurement.     

Numerical simulation of friction stir butt welding process for AA5083-H18 sheets

Thermo-mechanical simulation of the friction stir butt welding (FSBW) process was performed for AA5083-H18 sheets, utilizing a commercial finite volume method (FVM) code, STAR-CCM+, which is based on the Eulerian formulation. Distributions of temperature and strain rate histories were calculated under the steady state condition and simulated temperature distributions (profiles and peak values) were compared with experiments. It was found that including proper thermal boundary condition for the backing plate (anvil) is critical for accurate simulation results. Based on the simulation, thermal and deformation histories of material elements were also calculated, useful to predict material characteristics of the weld such as hardness or grain size, and possibly for the susceptibility of weld to abnormal grain growth (AGG) after post-weld heat treatment.     

Comprehensive numerical analysis of a three-pass bead-in-slot weld and its critical validation using neutron and synchrotron diffraction residual stress measurements

The current paper presents a finite element simulation of the residual stress field associated with a three pass slot weld in an AISI 316LN austenitic stainless steel plate. The simulation is split into uncoupled thermal and mechanical analyses which enable a computationally less expensive solution. A dedicated welding heat source modelling tool is employed to calibrate the ellipsoidal Gaussian volumetric heat source by making use of extensive thermocouple measurements and metallographic analyses made during and after welding. The mechanical analysis employs the Lemaitre–Chaboche mixed hardening model. This captures the cyclic mechanical response which a material undergoes during the thermo-mechanical cycles imposed by the welding process. A close examination of the material behaviour at various locations in the sample during the welding process, clearly demonstrates the importance of defining the correct hardening and high temperature softening behaviour. The simulation is validated by two independent diffraction techniques. The well-established neutron diffraction technique and a very novel spiral slit X-ray synchrotron technique were used to measure the residual stress–strain field associated with the three-pass weld. The comparison between the model and the experiment reveals close agreement with no adjustable parameters and clearly validates the used modelling procedure.     

石油钻机盘式刹车副材料选配的实验研究

在 MMW- 1型摩擦磨损试验机上 ,通过变温摩擦磨损特性试验 ,对优选出的 2种刹车盘表面堆焊材料和研制出的 2种刹车块材料进行了选配 ,并对各刹车副的摩擦学性能进行了分析与评价 .结果表明 ,摩擦偶件对刹车副材料的摩擦学性能有一定的影响 ,因此在进行材料的选配试验时应考虑偶件的匹配问题 .优选出的 2种表面堆焊材料与所研制的 2种刹车块材料组成摩擦副时具有较高的平均摩擦系数和热摩擦系数以及优良的高温耐磨性能 ,其中第二种表面堆焊材料与所研制的第二种无石棉刹车块材料组成摩擦副时的摩擦学性能指标最优 ,可以作为选配出的最优刹车副材料     

爆炸法消除焊接接头残余应力的数值模拟

利用非线性动力有限元法对爆炸处理消除焊接接头残余应力的全过程进行了数值模拟。首先，采用温度场与位移场的间接耦合方法计算了钢板对接焊的焊后冷却及残余应力的生成过程，求得焊接接头处由高温冷却到室温由于变形受到阻碍而产生的不均匀的残余塑性变形和应力。然后，在焊缝区引入移动的爆炸载荷，计算了爆炸波作用下该钢板焊接接头附近应力的变化。计算结果表明，爆炸处理可引起板内应力的重新分布，从而有效地释放超过塑性极限的残余应力。利用炸药爆炸消除大型焊接结构残余应力是一种经济有效的方法，本文的数值模拟为研究炸药爆炸消除焊接结构残余应力的机理提供了有力的工具。     

Real-Time Weld Zone Strain/Slope Measurements Using the Interferometric Strain/Slope Rosette Technique

A laser-based optical technique, the Interferometric Strain/Slope Rosette (ISSR) technique, was used to measure real-time deformations in welding heat-affected zones. This was accomplished by measuring simultaneously real-time in-plane strains, out-of-plane slopes and weld plate temperature from both carbon and stainless steel plates. All strain/slope results demonstrated a strong sensitivity to such welding parameters as temperature, weld length and heat input. Accuracy of the measurements was studied. The strain/slope responses were also proven to be predictable, with measured strains comparable to released strains measured by resistance strain rosette/hole-drilling and ISSR/ring-core cutting.     

Metal Flow during Friction Stir Welding of 7075-T651 Aluminum Alloy

Bronze foil of 0.1 mm thickness was placed between faying surfaces of two plates to be butt-welded as marker material to reveal the flow behavior of weld metal during friction stir welding of 7075-T651 aluminum alloy. By tracing the bronze foil fragments in the weld after welding, the metal flow behavior during the welding process was revealed. Besides, the tool forces in the welding process were measured by the octagonal loop resistance turning dynamometer to expound the periodic variation of metal flow pattern. Results show that the flow behavior of the weld metal is different along the thickness direction. The flow pattern presents a periodic variation, and a formula has been proposed to calculate the periodicity of the metal flow. In addition, the weld nugget zone presents a “spoon” shape and the fine grains at the spoon handle and those at the spoon bowl are originated from different zones. A plastic metal flow model in FSW was proposed based on the results. Furthermore, the formation of defects was explained by researching the weld metal flow behavior.     

Numerical analysis of the heat and fluid flow in a weld pool with a dynamic keyhole

In keyhole plasma arc welding, the interaction between the keyhole and the weld pool occurs when the keyhole appears inside the weld pool. The change of the keyhole shape and dimensions has direct effect on the heat and fluid flow in the weld pool, and the latter will also influence the keyhole geometry. In this study, the coupled behaviors of weld pool and keyhole are treated to develop a three-dimensional model for analyzing the heat and fluid flow inside a weld pool with a dynamic keyhole. In view of the characteristics of PAW process, a combined volumetric heat source model (double-ellipsoid plus conic body source) is established, and one of its distribution parameters is adjusted dynamically with the variation of the depth of keyhole. The physical phenomena, such as the weld pool development, the keyhole formation, the evolution of fluid flow and thermal field, the full-penetration of the test plates, and the transformation from a blind keyhole to an open keyhole, are quantitatively analyzed. The numerical results reveal the regularity of fluid flow in weld pool with a keyhole. The calculated keyhole shape and the fusion zone of plasma arc welds are compared with the experimental measurements. Both agree with each other generally. It lays foundation for optimizing the welding process parameters and improving the stability of plasma arc welding process.     

Measurement of residual stress in the weld overlay piping components

In general industry, especially in the nuclear industry, welding overlay repair is an important repair method mainly used to rebuild piping systems suffering from intergranular stress-corrosion cracking (IGSCC).The pipe surface is mechanically ground to obtain a smooth surface after the welding overlay repair. A better understanding of the effect of repair and grinding processes on the residual stresses at the surface of weld overlay is required. To obtain this understanding, it is necessary to measure directly the distribution of residual stresses on the specimen. It is expected that compressive residual stress should be induced at the inner wall surface of the pipe for prevention of IGSCC.The performance evaluation of welding overlay repair relies on whether or not the level and characteristic of the residual stress can be measured accurately. In this study, the hole-drilling strain-gage method, using the incremental drilling technique, was adopted to estimate the residual stresses on the inner and outer walls of the weld overlay pipe. The experimental results indicate that the residual stress at the pipe inner surface is compressive while that of the outer surface is tensile. Also, it is found that the depth affected by grinding is about 1.016 mm.     

A new strategy for the numerical modeling of a weld pool

Welding processes involve high temperatures and metallurgical and mechanical consequences that must be controlled. For this purpose, numerical simulations have been developed to study the effects of the process on the final structure. During the welding process, the material undergoes thermal cycles that can generate different physical phenomena, like phase changes, microstructure changes and residual stresses and distortions. But the accurate simulation of transient temperature distributions in the part needs to carefully take account of the fluid flow in the weld pool. The aim of this paper is thus to propose a new approach for such a simulation taking account of surface tension effects (including both the “curvature effect” and the “Marangoni effect”), buoyancy forces and free surface motion.The proposed approach is validated by two numerical tests from the literature: a sloshing test and a plate subjected to a static heat source. Then, the effects of the fluid flow on temperature distributions are discussed in a hybrid laser/arc welding example.     

Measurement of Creep Deformation across Welds in 316H Stainless Steel Using Digital Image Correlation

Spatially resolved measurement of creep deformation across weldments at high temperature cannot be achieved using standard extensometry approaches. In this investigation, a Digital Image Correlation (DIC) based system has been developed for long-term high-temperature creep strain measurement in order to characterise the material deformation behaviour of separate regions of a multi-pass weld. The optical system was sufficiently stable to allow a sequence of photographs to be taken suitable for DIC analysis of creep specimens tested at a temperature of 545 °C for over 2000 h. The images were analysed to produce local creep deformation curves from two cross-weld samples cut from contrasting regions of a multi-pass V-groove weld joining thick-section AISI Type 316H austenitic stainless steel. It is shown that for this weld, the root pass is the weakest region of the structure in creep, most likely due to the large number of thermal cycles it has experienced during the fabrication process. The DIC based measurement method offers improved spatial resolution over conventional methods and greatly reduces the amount of material required for creep characterisation of weldments.     

Simulation of temperature fields in arc and beam welding

 Heat and mass transfer in arc and beam welding is considered. The main objectives are analysis of the heat transfer in the weld pool and the workpiece and to demonstrate how computer simulation can be used as a tool to predict the temperature distribution as the determining element of the heat effects of welding. Simulation results of two particular welding processes are compared and validated with measurements. Received on 26 July 1999     

Thermal bending analysis of shear-deformable laminated anisotropic plates by the GDQ method

The generalized differential quadrature (GDQ) method was used to determine the inter-laminar stresses and deflections in a laminated rectangular anisotropy plate under thermal bending involving the effect of shear deformation. We obtained the non-dimensional stresses and transverse center deflection in cross-ply and angle-ply anti-symmetric, anisotropic laminates subjected to thermal load with sinusoidal temperature distribution. We found that the shear deformation has significant effects on the stresses and deflections for laminated anisotropic plate with moderately side-to-thickness ratio under thermal load and bending state.     

点焊瞬态热过程的有限元分析

基于ANSYS有限元分析系统,建立了用于点焊瞬态热过程分析的电热耦合有限元模型．分析中考虑了随温度变化的材料特性参数、相变问题以及对流边界条件等,对点焊过程中的接触问题进行了适当简化,以避免耗时的迭代算法．通过对低碳钢薄板的分析,得到了整个焊接过程的热历程以及焊件各部位的温度分布,并且可以求得焊核及热影响区的形状和尺寸,同时本模型也可用于其它材料的点焊过程分析．     

双列直插器件(DIP)焊接过程中的应力评价

为探讨陶瓷封装双列直插器件在焊接后出现开裂的问题,应用云纹干涉法和Twyman/Green干涉法实时测试了该类型器件在焊接过程中的面内和离面变形情况,并将测试数据与有限元法相结合,评估了焊接过程中器件内部因印制板变形而产生的应力大小。由此对原先"焊接导致开裂"的说法做出了评价。同时,通过器件的变形测试,探讨了优化焊接工艺的方法。研究结果表明,焊接顺序对器件内部热应力和器件变形影响不大,而适当提高器件高度可有效减小焊接时的热应力。     

Effect of welding process on fatigue crack growth behaviour of austenitic stainless steel welds in a low alloy (Q & T) steel

Fatigue crack growth behaviour from a lack of penetration (LOP) defect in austenitic stainless steel weld metals of cruciform joints made of a low alloy high strength (Q & T) steel has been studied to understand the effect of two welding processes, namely, shielded metal arc welding (SMAW) and flux cored arc welding (FCAW). Fatigue crack growth studies were carried out at a stress ratio of R = 0 and a frequency of 90 to 110 Hz in a resonant testing equipment (Rumul, Model:8601). Crack growth rates were relatively lower in the weld metal obtained by flux cored arc welding process. Microstructural features observed revealed marked difference in the morphology of delta ferrite for the welded joints obtained from the above two welding processes. Long streaks of delta ferrite in austenite matrix were found in case of SMAW-weld metal which seem to have lowered the resistance to the fatigue crack propagation. A discontinuous network of delta ferrite found in austenite matrix in the case of FCAW-weld metal seems to have contributed to slower propagation of fatigue crack. Fractographic features also substantiate the observed trends in the fatigue crack growth behaviour.     

Photomechanical properties of some birefringent polymers around their glass transition temperatures

This paper describes an investigation and comparison of the optical and mechanical properties of the three polymers—PMMA (polymethyl methacrylate), CT200 and MY750 (both based on bisphenol-A epichlorohydrin). The work was undertaken with the specific purpose of assessing the suitability of these polymers for use in contact studies involving three-dimensional photoelasticity and the stress-freezing technique. The optical property investigated was the variation of photoelastic fringe constant with maximum stress-freezing temperature. The mechanical properties sought were the variation of Young's modulus with temperature and the stress-strain behavior at the stress-freezing temperature. The effects of the magnitude of stress and the soak time in the thermal cycle were also investigated for the MY750 resin. The results provide the optimum peak temperature for the thermal cycle to achieve repeatable values of Young's modulus and fringe constant during stress freezing. The nonlinear stress-strain behavior is quantified and should be a useful reference. The dependence of strain on load and soak time is also shown and is useful in specifying the optimum cycle time for stress freezing and the appropriate stress level. It was concluded that the resin MY750 was the most suitable for photoelastic applications which involved high localized stress, such as contact problems or fracture mechanics studies.