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Research Papers: Design and Analysis

Finite Element Simulation of Welding Sequences Effect on Residual Stresses in Multipass Butt-Welded Stainless Steel Pipes

[+] Author and Article Information
S. Feli1

 Department of Mechanical Engineering, Razi University, Kermanshah 67149, I. R. IranFelisaeid@gmail.com

M. E. Aalami Aaleagha

 Department of Mechanical Engineering, Razi University, Kermanshah 67149, I. R. Iranme_aalami_aleagha@yahoo.com

M. Foroutan

 Department of Mechanical Engineering, Razi University, Kermanshah 67149, I. R. Iranforoutan@razi.ac.ir

E. Borzabadi Farahani

 Department of Mechanical Engineering, Razi University, Kermanshah 67149, I. R. Iranehsan.farahani@yahoo.com

1

Corresponding author.

J. Pressure Vessel Technol 134(1), 011209 (Dec 07, 2011) (9 pages) doi:10.1115/1.4004571 History: Received June 16, 2010; Revised April 24, 2011; Published December 07, 2011; Online December 07, 2011

In this paper, a finite element simulation, based on abaqus software is presented for analyzing the temperature history and the residual stress states in multipass welds in stainless steel pipe. The uncoupled thermal–mechanical a three-dimensional (3D) model and a two-dimensional (2D) model are developed. The volumetric heat source with double ellipsoidal distribution for front and rear heat source, proposed by Goldak and Akhlaghi, has also been used. Furthermore, a moving heat source has been modeled by abaqus subroutine DFLUX. A user subroutine FILM has also been used to simulate the combined thermal boundary conditions. The results of both a 3D model and a 2D axisymmetric model which are compared with the available experimental measurements show good agreements. Predictions show that the axial and hoop residual stresses in a 3D model and a 2D axisymmetric model have the same distributions in all locations except the starting point of welding. The effects of welding sequences on the thermal and structural analysis are also investigated. Four types of welding sequences for circular welds of pipe have been used and thermal history and axial and hoop residual stresses are compared. Predictions show that for other locations (except the starting point of welding) there are no important differences of axial and hoop residual stresses for welding sequences and they have the same distribution along axial direction.

Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 1

Welding direction

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Figure 2

(a) 3D finite element model of pipe and (b) 2D finite element model of pipe

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Figure 3

Thermal history at 3 mm of weld centerline on the inside surface after the first welding where circumferential angle θ is 180 deg

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Figure 4

Thermal history at 8 mm of weld centerline on the inside surface after the first welding where circumferential angle θ is 180 deg

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Figure 5

Thermal cycles at 3 mm of weld centerline in 90 deg, 180 deg, and 270 deg locations on the inside surface during the first welding.

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Figure 6

Temperature field distribution at the end of second pass of welding in 3D FE simulation

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Figure 7

Temperature field distribution at the end of second pass of welding in 2D FE simulation

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Figure 8

Axial stress distributions of the welded pipe in 3D FE simulation

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Figure 9

Axial stress distributions of the welded pipe in 2D FE simulation

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Figure 10

Axial residual stress along axial direction at locations with 180 deg on the inside surface

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Figure 11

Axial residual stress along axial direction at locations with 180 deg on the outside surface

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Figure 12

Hoop residual stress distribution at locations with 180 deg on the inside surface

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Figure 13

The four type welding sequences for butt-welded of pipe

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Figure 14

Thermal cycles at 7.4 mm of weld centerline in 90 deg location on the inside surface at various welding sequences

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Figure 15

Thermal cycles at 14 mm of weld centerline in 90 deg location on the outside surface at various welding sequences

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Figure 16

Residual axial stress distribution at first welding sequence

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Figure 17

Residual axial stress distribution at second welding sequence

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Figure 18

Residual axial stress distribution at third welding sequence

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Figure 19

Residual axial stress distribution at fourth welding sequence

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Figure 20

Axial residual stress distribution at the start of welding on the inside surface for various welding sequences

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Figure 21

Axial residual stress distribution at the start of welding on the outside surface for various welding sequences

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Figure 22

Hoop residual stress distribution at the start of welding on the inside surface for various welding sequences

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Figure 23

Axial residual stress distribution at the location 90 deg on the inside surface for various welding sequences

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Figure 24

Axial residual stress distribution at the location 90 deg on the outside surface for various welding sequences

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Figure 25

Hoop residual stress distribution at the location 90 deg on the inside surface for various welding sequences

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