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Research Papers: Materials and Fabrication

Control of Welding Residual Stress and Deformation of the Butt Welded Ultrathick Tube-Sheet: Effect of Applied Load

[+] Author and Article Information
Wenchun Jiang

State Key Laboratory of Heavy Oil Processing,
College of Chemical Engineering,
China University of Petroleum (East China),
Qingdao 266555, PR China;
Neutron Science Division, Korea
Atomic Energy Research Institute,
Daejeon 305-353, South Korea
e-mail: jiangwenchun@upc.edu.cn

J. M. Gong

School of Mechanical and Power Engineering,
Nanjing University of Technology Nanjing,
210009, PR China

Wanchuck Woo

Neutron Science Division, Korea Atomic Energy
Research Institute, Daejeon 305-353,
South Korea

Y. F. Wang

School of Mechanical and Power Engineering,
Nanjing University of Technology, Nanjing,
210009, PR China

S. T. Tu

Key Laboratory of Pressure System and Safety (MOE), School of Mechanical and Power Engineering,
East China University of Science and Technology,
Shanghai 200237, PR China

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received August 25, 2011; final manuscript received May 30, 2012; published online November 21, 2012. Assoc. Editor: Frederick W. Brust.

J. Pressure Vessel Technol 134(6), 061406 (Nov 21, 2012) (8 pages) doi:10.1115/1.4007037 History: Received August 25, 2011; Revised May 30, 2012

Residual stresses and deformation in the butt welding of an ultrathick tube-sheet in a large scale reactor are predicted by finite element method. The effect of applied load on residual stress and deformation has been discussed. When the tube-sheet is welded without any constraint and applied load, large angular deformation is generated due to the large amount of heat input, the nonuniform temperature distribution, and shrinkage. In order to decrease the angular deformation, a heavy load is applied at both ends of tube-sheet. With the applied load increase from 5 × 104 to 45 × 104 kg, the deformation decreases but the residual stress increases. When the load is beyond 45 × 104 kg, the deformation mode is changed from angular deformation to arch deformation. An optimized load of 45 × 104 kg is determined. The zone of peak residual stress is increased as the applied load increases. Too heavy a load generates a serious constraint on deformation, which in turn leads to higher residual stress.

Copyright © 2012 by ASME
Topics: Deformation , Welding , Stress
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Figures

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Fig. 1

Welding photograph of EO tube-sheet on site

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Fig. 2

Sketching diagram of the tube-sheet welding

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Fig. 4

Welding sequence and passes

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Fig. 5

Finite element meshing

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Fig. 6

Residual stress contours of S11 (a), S22 (b), and S33 (c) without load

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Fig. 7

The deformation contour without load

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Fig. 8

Residual stress distribution along the top surface

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Fig. 9

Through-wall thickness residual stress along the center line of the weld metal

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Fig. 10

Through-wall residual stress distributions at the HAZ line

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Fig. 11

Residual stress contours of S11 (a), S22 (b), and S33 (c) with a load of 3 × 105 kg

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Fig. 12

Deformation with a load of 3 × 105 kg

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Fig. 13

The deformation contour with the applied load of 50 × 103 kg (a), 150 × 103 kg (b), 250 × 103 kg (c), 350 × 103 kg (d), and 450 × 103 kg (e)

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Fig. 14

The deformation contour with the applied load of 550 × 103 kg (a), 650 × 103 kg (b), and 750 × 103 kg (c)

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Fig. 15

Transverse stress with the applied load of 50 × 103 kg (a), 150 × 103 kg (b), 250 × 103 kg (c), 350 × 103 kg (d), 450 × 103 kg (e), 550 × 103 kg (f), 650 × 103 kg (g), and 750 × 103 kg (h)

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Fig. 16

Effect of applied load on peak stress

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