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Journal of Pressure Vessel Technology | Volume 132 | Issue 1 | Research Paper
Research Papers: Materials and Fabrication

Optimization of a Weld Overlay on a Plate Structure

[+] Author and Article Information
John Goldak

 Carleton University, Ottawa, ON K1S 5B6, Canadajgoldak@mrco2.carleton.ca

Mahyar Asadi

 Carleton University, Ottawa, ON K1S 5B6, Canada

Jianguo Zhou, Stanislav Tchernov, Dan Downey

 Goldak Technologies Incorporated, Ottawa, ON K1V 7C2, Canada

J. Pressure Vessel Technol 132(1), 011402 (Dec 09, 2009) (9 pages) doi:10.1115/1.4000511 History: Received January 29, 2009; Revised September 22, 2009; Published December 09, 2009; Online December 09, 2009
Article
References
Figures
Tables

An overlay weld repair procedure on a 1066.8×1066.8 mm2 square plate 25.4 mm thick was simulated to compute the 3D transient temperature, microstructure, strain, stress, and displacement of the overlay weld repair procedure. The application for the overlay was the repair of cavitation erosion damage on a large Francis turbine used in a hydroelectric project. The overlay weld consisted of a 4×6 pattern of 100×100 mm2 squares. Each square was covered by 15 weld passes. Each weld pass was 100 mm long. The total length of weld in the six squares was 36 m. The welds in each square were oriented either front-to-back or left-to-right. The welding process was shielded metal arc. The analysis shows that alternating the welding direction in each square produces the least distortion. A delay time of 950 s between the end of one weld pass and the start of the next weld pass was imposed to meet the requirement of a maximum interpass temperature to 50°C.
Copyright © 2010 by American Society of Mechanical Engineers
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References

1
Chakravarti, A. P., Malik, L. M., Rao, A. S., and Goldak, J. A., 1987, “Prediction of Distortion in Overlayed Repair Welds,” "Proceedings of the Fifth International Conference on Thermal Problems", Montreal, Canada, June 29, pp. 1120–1141.
2
http://www.goldaktec.com
3
Watt, D. F., Coon, L., Bibby, M. J., Goldak, J. A., and Henwood, C., 1988, “Modelling Microstructural Development in Weld Heat-Affected Zones, (Part A),” Acta Metall., 36 (11), pp. 3029–3035.  [CrossRef]
4
Henwood, C., Bibby, M. J., Goldak, J. A., and Watt, D. F., 1988, “Coupled Transient Heat Transfer-Microstructure Weld Computations (Part B),” Acta Metall., 36 (11), pp. 3037–3046.  [CrossRef]
5
Goldak, J., and Akhlaghi, M., 2005, "Computational Welding Mechanics", Springer, New York.
6
Anderson, B. A. B., 1978, “Thermal Stress in Submerged-Arc-Welded Joint Considering Phase Transformation,” ASME J. Eng. Mater. Technol., 100 , pp. 356–362.
7
Paradowska, A., Price, J. W. H., Ibrahim, R., and Finlayson, T., 2005, “A Neutron Diffraction Study of Residual Stress Due to Welding,” J. Mater. Process. Technol., 164–165 , pp. 1099–1105.  [CrossRef]
8
Goldak, J., Zhou, J., Tchernov, S., Downey, D., Wang, S., and He, B., 2005, “Predicting Distortion and Residual Stress in Complex Welded Structures by Designers,” "Proceedings of the Seventh International Trends in Welding Research", Callaway Gardens Resort, Pine Mountain, GA, pp. 531–539.
9
Goldak, J. A., Chakravarti, A., and Bibby, M. J., 1984, “A New Finite Element Model for Welding Heat Sources,” Metall. Trans. B, 15B , pp. 299–305.  [CrossRef]
10
Kirkaldy, J., and Venugoplan, D., 1983, “Prediction of Micro-Structure and Hardenability in Low Alloy Steels, Phase Transformation in Ferrous Alloys,” "Proceedings of International Conference", Oct. 4–6.
11
Simo, J. C., 1998, "Numerical Analysis of Classical Plasticity, Handbook for Numerical Analysis", P.G.Ciarlet and J.J.Lions, eds., Elsevier, Amsterdam, Vol. 4 .
12
Goldak, J., 2008, “Thermo-Mechanical Modelling of Welding Induced Strains: Numerical Validation of the Weld Build-Up Process,” DRDC Atlantic Paper No. CR 2008-283.
13
Radaj, D., and Lindgren, L. -E., 2006, “Verification and Validation in Computational Weld Mechanics,” "Mathematical Modeling of Weld Phenomena 8", H.Cerjak, H.K. D. H.Bhadeshia, and E.Kozenchnik, eds., TuGraz, Graz, Austria, pp. 1039–1051.
14
Goldak, J., 2008, “Distortion and Residual Stress in Welded Structures: The Next Generation,” "Proceedings of the Eighth International Trends in Welding Research", Callaway Gardens Resort, Pine Mountain, GA, June 2–5.
15
Goldak, J., Johnsson, E., El-Zein, M., Zhou, J., Tchernov, S., Downey, D., Wang, Sh., and Coulombe, M., 2006, “The L2 Norm of the Deviation Between the Measured and Computed Transient Displacement Field in a Test Weld,” "Proceedings of the Eighth International Seminar Numerical Analysis of Weldability", Graz, Austria.

Figures

Grahic Jump Location
+The geometry of the overlay weld repair simulation described in Ref. 1 is shown
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The geometry of the overlay weld repair simulation described in Ref. 1 is shown
Figure 1

The geometry of the overlay weld repair simulation described in Ref. 1 is shown

Grahic Jump Location
+This cross section of the block for one overlay 100 mm square shows the FEM mesh for the filler metal
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This cross section of the block for one overlay 100 mm square shows the FEM mesh for the filler metal
Figure 2

This cross section of the block for one overlay 100 mm square shows the FEM mesh for the filler metal

Grahic Jump Location
+The FEM mesh of several blocks of overlay 100 mm square are shown embedded the structure being repaired
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The FEM mesh of several blocks of overlay 100 mm square are shown embedded the structure being repaired
Figure 3

The FEM mesh of several blocks of overlay 100 mm square are shown embedded the structure being repaired

Grahic Jump Location
+The FEM mesh of 6×4 checker board pattern of blocks of 100 mm overlay squares are shown together with stiffening gussets of the structure being repaired
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The FEM mesh of 6×4 checker board pattern of blocks of 100 mm overlay squares are shown together with stiffening gussets of the structure being repaired
Figure 4

The FEM mesh of 6×4 checker board pattern of blocks of 100 mm overlay squares are shown together with stiffening gussets of the structure being repaired

Grahic Jump Location
+The temperature in K at a virtual thermocouple located at the centroid of the bottom of the plate is plotted versus time. Each peak is associated with one weld pass in one block.
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The temperature in K at a virtual thermocouple located at the centroid of the bottom of the plate is plotted versus time. Each peak is associated with one weld pass in one block.
Figure 5

The temperature in K at a virtual thermocouple located at the centroid of the bottom of the plate is plotted versus time. Each peak is associated with one weld pass in one block.

Grahic Jump Location
+The decay of the maximum temperature in the structure between two weld passes is shown as a function of time for a maximum interpass temperature of 50°C. The delay time for any higher maximum interpass temperature can be read from the graph.
View Large  |  Save Figure  |  Download Slide (.ppt)
The decay of the maximum temperature in the structure between two weld passes is shown as a function of time for a maximum interpass temperature of 50°C. The delay time for any higher maximum interpass temperature can be read from the graph.
Figure 6

The decay of the maximum temperature in the structure between two weld passes is shown as a function of time for a maximum interpass temperature of 50°C. The delay time for any higher maximum interpass temperature can be read from the graph.

Grahic Jump Location
+The phase fraction of martensite is shown for the front-to-back overlay
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The phase fraction of martensite is shown for the front-to-back overlay
Figure 7

The phase fraction of martensite is shown for the front-to-back overlay

Grahic Jump Location
+The phase fraction of ferrite is shown for the front-to-back overlay
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The phase fraction of ferrite is shown for the front-to-back overlay
Figure 8

The phase fraction of ferrite is shown for the front-to-back overlay

Grahic Jump Location
+The hardness is shown for the front-to-back overlay. The blue denoting zero hardness is because the algorithm only computes hardness if the material point transformed to austenite.
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The hardness is shown for the front-to-back overlay. The blue denoting zero hardness is because the algorithm only computes hardness if the material point transformed to austenite.
Figure 9

The hardness is shown for the front-to-back overlay. The blue denoting zero hardness is because the algorithm only computes hardness if the material point transformed to austenite.

Grahic Jump Location
+The εzz strain as a function of time for strain gauge at the center of the bottom surface
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The εzz strain as a function of time for strain gauge at the center of the bottom surface
Figure 10

The εzz strain as a function of time for strain gauge at the center of the bottom surface

Grahic Jump Location
+The εzz strain as a function of time for strain gauge at the center of the bottom surface for longer time
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The εzz strain as a function of time for strain gauge at the center of the bottom surface for longer time
Figure 11

The εzz strain as a function of time for strain gauge at the center of the bottom surface for longer time

Grahic Jump Location
+Left-to-right distortion magnified ten times at 1,000,000 s
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Left-to-right distortion magnified ten times at 1,000,000 s
Figure 12

Left-to-right distortion magnified ten times at 1,000,000 s

Grahic Jump Location
+Front-to-back distortion magnified ten times at 1,000,000 s
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Front-to-back distortion magnified ten times at 1,000,000 s
Figure 13

Front-to-back distortion magnified ten times at 1,000,000 s

Grahic Jump Location
+Checker board distortion magnified ten times at 1,000,000 s
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Checker board distortion magnified ten times at 1,000,000 s
Figure 14

Checker board distortion magnified ten times at 1,000,000 s

Grahic Jump Location
+Difference of left-to-right distortion to checker board distortion magnified ten times at 1,000,000 s
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Difference of left-to-right distortion to checker board distortion magnified ten times at 1,000,000 s
Figure 15

Difference of left-to-right distortion to checker board distortion magnified ten times at 1,000,000 s

Grahic Jump Location
+Difference of front-to-back distortion to checker board distortion magnified ten times at 1,000,000 s
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Difference of front-to-back distortion to checker board distortion magnified ten times at 1,000,000 s
Figure 16

Difference of front-to-back distortion to checker board distortion magnified ten times at 1,000,000 s

Grahic Jump Location
+Difference of left-to-right distortion to front-to-back distortion magnified ten times at 1,000,000 s
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Difference of left-to-right distortion to front-to-back distortion magnified ten times at 1,000,000 s
Figure 17

Difference of left-to-right distortion to front-to-back distortion magnified ten times at 1,000,000 s

Grahic Jump Location
+The temperature at the point at which a thermocouple is located is plotted versus time. This figure is from Ref. 12.
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The temperature at the point at which a thermocouple is located is plotted versus time. This figure is from Ref. 12.
Figure 18

The temperature at the point at which a thermocouple is located is plotted versus time. This figure is from Ref. 12.

Grahic Jump Location
+The εzz strain as a function of time for strain gauge 1 on the top surface of the 100×100 is shown. This figure is from Ref. 12.
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The εzz strain as a function of time for strain gauge 1 on the top surface of the 100×100 is shown. This figure is from Ref. 12.
Figure 19

The εzz strain as a function of time for strain gauge 1 on the top surface of the 100×100 is shown. This figure is from Ref. 12.

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