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Research Papers: Design and Analysis

Numerical Investigation on Heat Transfer and Residual Stress in a Butt Welded Plate

[+] Author and Article Information
D. Kumaresan

Structural Dynamics and Design Analysis Division, Liquid Propulsion System Centre, Trivandrum 695547, Indiad_kumaresan_cbe@rediffmail.com

A. K. Asraff, R. Muthukumar

Structural Dynamics and Design Analysis Division, Liquid Propulsion System Centre, Trivandrum 695547, India

J. Pressure Vessel Technol 133(4), 041206 (May 16, 2011) (10 pages) doi:10.1115/1.4002859 History: Received March 04, 2009; Revised September 20, 2010; Published May 16, 2011; Online May 16, 2011

It is a well known fact that during welding, the metal at the welding zone gets melted and then solidifies, which results in shrinkage in all directions. Residual strain and stress distributions coming from shrinking are largely influenced by the nature and configuration of the welding process, metallurgical characteristics of weld, and the geometrical shape of the weld joint. The residual stress mainly depends on the thermal history cycle through which the specimen undergoes in the welding process. So these thermal history cycles are to be known in order to get a better knowledge of the welding phenomenon and to minimize the risk of failures. In this work, a detailed analysis has been carried out for predicting the heat flow pattern and stress distribution in an aluminum alloy plate during welding. In this study, the modified double ellipsoidal heat source distribution pattern is modeled and considered for the weld pool design. Elastic-plastic material properties at various temperatures are also considered for simulation. A detailed finite element analysis is carried out to predict the welding residual stress. In this, thermal analysis is carried out for actual variable welding speed and these transient thermal histories at various locations were numerically predicted and compared with experimental results. Further, these thermal results are used to predict the residual stress on the weld plate using finite element method.

Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Temperature and stress distribution pattern

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Figure 2

3D heat density distribution

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Figure 3

3D finite element model of the specimen

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Figure 4

Temperature dependent material properties

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Figure 5

Thermocouples (a) (⋅) and residual stress measurement (b) (x) location on welded plates

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Figure 6

Schematic diagram of clamping of the plates

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Figure 7

Variation of welding speed with respect to time

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Figure 8

Temperature distribution pattern in the plate

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Figure 9

Temperature distribution perpendicular to the weld

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Figure 10

Transient temperature distribution at various points

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Figure 11

Temperature history at P1 (experimental and FEM)

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Figure 12

Temperature history at P2 (experimental and FEM)

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Figure 13

Temperature history at P3 (experimental and FEM)

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Figure 14

Temperature history at P4 (experimental and FEM)

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Figure 15

Temperature history at P5 (experimental and FEM)

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Figure 16

Variation of longitudinal direction stress with respect to time

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Figure 17

Deformation of the welded plate before removal of clamp

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Figure 18

Deformation of the weld plate after removal of clamp

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Figure 19

Residual stress in longitudinal direction

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Figure 20

Residual stress in transverse direction

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Figure 21

Longitudinal residual stress in transverse X direction

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Figure 22

Transverse residual stress in longitudinal Z direction

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