Research Papers: NDE

Investigation of Clamping Effect on the Welding Residual Stress and Deformation of Monel Plates by Using the Ultrasonic Stress Measurement and Finite Element Method

[+] Author and Article Information
Yashar Javadi

Department of Mechanical Engineering,
Semnan Branch,
Islamic Azad University,
Km. 5 of Semnan-Damghan Road,
Semnan, Iran
e-mail: yasharejavadi@yahoo.com

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received August 20, 2013; final manuscript received April 23, 2014; published online September 15, 2014. Assoc. Editor: Albert E. Segall.

J. Pressure Vessel Technol 137(1), 011501 (Sep 15, 2014) (7 pages) Paper No: PVT-13-1138; doi: 10.1115/1.4027514 History: Received August 20, 2013; Revised April 23, 2014

Welding of nickel-based alloys is increasingly used in the industry to manufacture many important components of the marine industries, chemical processing, etc. In this study, a 3D thermomechanical finite element (FE) analysis is employed to evaluate residual stresses and deformations caused by the tungsten inert gas (TIG) welding of Monel 400 (Nickel-Copper alloy) plates. The FE results related to the residual stresses and deformations have been verified by using the hole-drilling stress measurement and common dimensional measurement tools, respectively. Residual stresses analyzed by the FE simulation are then compared with those obtained from ultrasonic stress measurement. The ultrasonic stress measurement is based on acoustoelasticity law, which presents the relation between the acoustic waves and the stress of material. The ultrasonic stress measurement is carried out by using longitudinal critically refracted (LCR) waves which are longitudinal ultrasonic waves propagated parallel to the surface inside the tested material. Two welded plates are experimentally prepared (with and without using clamp) to investigate the clamping effect on the welding residual stress and deformations. By utilizing the FE analysis along with the LCR method, the distribution of longitudinal residual stress could be achieved. It has been concluded that the applied methodologies are enough accurate to distinguish the clamping effect on the welding residual stresses and deformations of Monel plates.

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Fig. 1

Thermal and mechanical material properties of Monel 400 (extracted from Ref. [2])

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Fig. 2

FE model selected in this study (model No. 4)

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Fig. 3

The residual stresses analyzed by different six FE models (model No. 1–6: (a) and (b); model Nos. 4–6: (c) and comparison with hole-drilling results

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Fig. 4

Ultrasonic TOF measurement devices

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Fig. 5

Angular shrinkage produced after the welding of Monel plates

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Fig. 6

Longitudinal (axial) residual stress evaluated by FE, ultrasonic and hole-drilling method (plate 1; in Z = 110 mm)

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Fig. 7

Angular shrinkage (plate 1; in Z = 110 mm)

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Fig. 8

Clamping effect on the longitudinal residual stress (ultrasonic stress measurement in Z = 110 mm)

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Fig. 9

Clamping effect on the welding deformations




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