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Research Papers: Materials and Fabrication

On Residual Stress and Relief for an Ultra-Thick Cylinder Weld Joint Based on Mixed Hardening Model: Numerical and Experimental Studies

[+] Author and Article Information
Luyang Geng

Key Laboratory of Design and
Manufacture of Extreme Pressure Equipment,
School of Mechanical and Power Engineering,
Nanjing Tech University,
Nanjing 211816, China
e-mail: young@njtech.edu.cn

Shan-Tung Tu

Key Laboratory of Pressure Systems and
Safety (MOE),
School of Mechanical and Power Engineering,
East China University of
Science and Technology,
Shanghai 200237, China
e-mail: sttu@ecust.edu.cn

Jianming Gong

Key Laboratory of Design and
Manufacture of Extreme Pressure Equipment,
School of Mechanical and Power Engineering,
Nanjing Tech University,
Nanjing 211816, China
e-mail: gongjm@njtech.edu.cn

Wenchun Jiang

State Key Laboratory of Heavy Oil Processing,
College of Chemical Engineering,
China University of Petroleum (East China),
Qingdao 266580, China
e-mail: jiangwenchun@126.com

Wei Zhang

Key Laboratory of Design and
Manufacture of Extreme Pressure Equipment,
School of Mechanical and Power Engineering,
Nanjing Tech University,
Nanjing 211816, China
e-mail: hjzhw@njtech.edu.cn

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received September 5, 2017; final manuscript received May 13, 2018; published online June 18, 2018. Assoc. Editor: San Iyer.

J. Pressure Vessel Technol 140(4), 041405 (Jun 18, 2018) (9 pages) Paper No: PVT-17-1175; doi: 10.1115/1.4040315 History: Received September 05, 2017; Revised May 13, 2018

Residual stress distributions as welded and after local postwelding heat treatment (PWHT) of butted weld joint of a huge cylinder with ultra-thick wall were investigated by finite element (FE) simulations and measurement. Sequential coupling thermal-mechanical analyses were conducted with a generalized plane strain two-dimensional (2D) model to simulate the welding procedure bead by bead, combining with three-dimensional (3D) double-ellipsoid moving heat source and mixed isotropic–kinematic hardening plastic model. The simulation was validated by X-ray diffraction (XRD) measurements. Simulation results showed that local PWHT with heated band width of 0.5Rt can significantly reduce the residual stress on the outer surface of weld joint, but bring about harmful high tensile stress on inner surface due to bending moment induced by local radial thermal distortion. For the purpose to find out the appropriate heated band width of local PWHT, relations between stress relief and size of heated band were studied. Results show that the stresses on the inner surface reach a maximum value when the heated band width is less than 1Rt. Based on the simulation results and from the view point of lowering the stress level on the inner surface, the optimum width of 3Rt for heated band was proposed.

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Figures

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Fig. 1

Material properties for 13MnNiMoR steel

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Fig. 2

Dimensional details of the single U groove and welding sequence

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Fig. 3

Dimensional details of the cylinder and 2D FE model

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Fig. 4

Thermal cycle of the local PWHT

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Fig. 5

Setup of residual stress measurement by portable X-ray equipment on site

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Fig. 6

Locations of WRS measurement

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Fig. 7

Finite element meshing of the weld joint

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Fig. 8

Double-ellipsoid heat source incorporated into a 2D FE model

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Fig. 9

Predicted fusion zone, coarse grain HAZ, and fine grain HAZ compared with the macrograph of joint

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Fig. 10

Yield surface contract/expand and translate simultaneously due to cycle load

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Fig. 11

Three-dimensional FE model of the specimen under uniaxial cycle load

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Fig. 12

Cyclic softening curves at different temperatures obtained by experiments and FE simulation

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Fig. 13

Comparison of hoop stress distribution between simulation and measurements on outer surface

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Fig. 14

Contour of the highest temperature experienced during welding

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Fig. 15

Contour of the residual Mises stress within weld joint

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Fig. 16

Distribution of residual stress along axial Path1 on outer surface

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Fig. 17

Distribution of residual stress along axial Path2 on inner surface

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Fig. 18

Distribution of residual stress along radial Path3 at the weld center from inner surface to outer surface

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Fig. 19

Evolutions of stresses and displacements at center of weld on surface while heat from outside

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Fig. 20

Evolutions of stresses and displacements at center of weld on surface during uniform PWHT

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Fig. 21

Evolutions of stresses and displacements at center of weld on surface while heat from both surfaces

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Fig. 22

Relation between the maximum stresses along Path1 and Path2 and the heated band width

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