Abstract
In this work, the effect of multi-pass repair welding for removing a fatigue crack on the residual stress fields of GMA-welded S355J2 + N and S960QL structural steel T-joints was investigated. Two scenarios were considered, a fatigue crack smaller than half of the plate thickness, and a fatigue crack larger than half of the plate thickness. Samples were first welded in a T-joint structure; then, cracks were created on their weld toes by cyclic loading; after that, the cracks were machined at one or two sides of the plate, depending on the crack length, and finally, the sample was repaired by two-pass welding on each machined area. Longitudinal and transverse residual stresses were measured by the X-ray diffraction method. A 2D thermo-metallurgical-mechanical finite element model was developed for each sample to estimate the residual stress fields through the weldments. The results show that, regardless of the alloy or repairing in one or two sides, the repair welding increases the magnitude of the residual stresses compared to the initial weld, but the alloys show different behaviors during the process. In S960QL samples, during repair welding of one weld toe, the residual stress evolutions in previously welded areas that are not subjected to the repair welding occur due to the morphological changes in the phases and expansions and contractions, while for S355J2N samples, the expansions and contractions are mainly responsible for these changes.
Similar content being viewed by others
References
Goldak J, Asadi M (2014) Challenges in validation of computational weld mechanics code to compute residual stress and distortion in welds. J Press Vessel Technol Trans ASME 136:1–8. https://doi.org/10.1115/1.4024458
Dong P (2018) On repair weld residual stresses and significance to structural integrity. Weld World 62:351–362. https://doi.org/10.1007/s40194-018-0554-1
Song S, Dong P (2017) Residual stresses at weld repairs and effects of repair geometry. Sci Technol Weld Join 22:265–277. https://doi.org/10.1080/13621718.2016.1224544
Unsworth D, Driver RG, Li L (2020) Measurement and prediction of residual stresses in welded girders. J Constr Steel Res 169:106007. https://doi.org/10.1016/j.jcsr.2020.106007
Farajian M, Nitschke-Pagel T, Siegele D (2014) Welding residual stress behavior in tubular steel joints under multiaxial loading. HTM J Heat Treat Mater 69:6–13. https://doi.org/10.3139/105.110208
Charkhi M, Akbari D (2019) Experimental and numerical investigation of the effects of the pre-heating in the modification of residual stresses in the repair welding process. Int J Press Vessel Pip 171:79–91. https://doi.org/10.1016/j.ijpvp.2019.02.006
Elcoate CD, Dennis RJ, Bouchard PJ, Smith MC (2005) Three dimensional multi-pass repair weld simulations. Int J Press Vessel Pip 82:244–257. https://doi.org/10.1016/j.ijpvp.2004.08.003
Salerno G, Bennett CJ, Sun W, Becker AA (2017) Residual stress analysis and finite element modelling of repair-welded titanium sheets. Weld World 61:1211–1223. https://doi.org/10.1007/s40194-017-0506-1
Jiang W, Luo Y, Wang BY et al (2015) Neutron diffraction measurement and numerical simulation to study the effect of repair depth on residual stress in 316L stainless steel repair weld. J Press Vessel Technol Trans ASME 137:1–12. https://doi.org/10.1115/1.4028515
Withers PJ (2007) Residual stress and its role in failure. Reports Prog Phys 70:2211–2264. https://doi.org/10.1088/0034-4885/70/12/R04
SEW 088 Guidline (2017) Supplementary Sheet 1 to SEW 088: Weldable Fine Grain Steels: Guidelnes for Processing, Particulary for Fusion Wleding, Cold Cracking During Welding, Determining Appropriate Minimum Preheating, DIN German Institute for Standartization. Berlin, Germany
Schubnell J, Ladendorf P, Sarmast A et al (2021) Fatigue performance of high- and low-strength repaired welded steel joints. Metals (Basel) 11:293
Macherauch E, Müller P (1961) Das Sin^2ψ Verfahren von Rontgenographische Eigenspannungen. Z angew Phys 13:305–312
Goldak JA, Akhlaghi M (2005) Computational welding mechanics. Springer Science+Business Media, Inc., 233 Spring Street, New York
De A, DebRoy T (2004) A smart model to estimate effective thermal conductivity and viscosity in the weld pool. J Appl Phys 95:5230–5240. https://doi.org/10.1063/1.1695593
Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metall Trans B 15:299–305
Grong ØY (1997) Metallurgical modelling of welding, 2nd edn. The Institute of Materials, London
Gourd LM (1995) Principles of welding technology, 3rd edn. Edward Arnold, London
Aarbogh HM, Hamide M, Fjær HG et al (2010) Experimental validation of finite element codes for welding deformations. J Mater Process Technol 210:1681–1689. https://doi.org/10.1016/j.jmatprotec.2010.05.014
Bajpei T, Chelladurai H, Ansari MZ (2016) Mitigation of residual stresses and distortions in thin aluminium alloy GMAW plates using different heat sink models. J Manuf Process 22:199–210. https://doi.org/10.1016/j.jmapro.2016.03.011
Goyal VK, Ghosh PK, Saini JS (2009) Analytical studies on thermal behaviour and geometry of weld pool in pulsed current gas metal arc welding. J Mater Process Technol 209:1318–1336. https://doi.org/10.1016/j.jmatprotec.2008.03.035
Schenk T, Richardson IM, Kraska M, Ohnimus S (2009) Modeling buckling distortion of DP600 overlap joints due to gas metal arc welding and the influence of the mesh density. Comput Mater Sci 46:977–986. https://doi.org/10.1016/j.commatsci.2009.05.003
Lindgren L-E (2007) Computational welding mechanics: thermomechanical and microstructural simulations. Woodhead Publishing, Cambridge, London
Leblond JB, Devaux J (1984) A new kinetic model for anisothermal metallurgical transformations in steels including effect of austenite grain size. Acta Metall 32:137–146. https://doi.org/10.1016/0001-6160(84)90211-6
Koistinen DP (1959) A general equation prescribing the extent of the austenite-martensite transformation in pure iron-carbon alloys and plain carbon steels. Acta Metall 7:59–60
Saunders N, Miodownik P (1998) CALPHAD (Calculation of Phase Diagrams): A Comprehensive Guide, 1st ed. Elsevier Science Ltd, Langford Lane, Kidlington, Oxford
Trzaska J (2016) Calculation of critical temperatures by empirical formulae. Arch Metall Mater 61:981–986. https://doi.org/10.1515/amm-2016-0167
Seyffarth P, Meyer B, Scharff A (2018) Großer Atlas Schweiß-ZTU-Schaubilder, 2nd ed. DVS Media GmbH, Dusseldorf
Belytschko T, Liu WK, Moran B, Elkhodary KI (2014) Nonlinear finite elements for continua and structures, 2nd ed. John Wiley & Sons, Ltd, Hoboken
Sarmast A, Serajzadeh S (2019) The influence of welding polarity on mechanical properties, microstructure and residual stresses of gas tungsten arc welded AA5052. Int J Adv Manuf Technol 105:3397–3409. https://doi.org/10.1007/s00170-019-04580-7
Lindgren LE (2001) Finite element modeling and simulation of welding. part 2: Improved material modeling. J Therm Stress 24:195–231. https://doi.org/10.1080/014957301300006380
Hamelin CJ, Muránsky O, Smith MC et al (2014) Validation of a numerical model used to predict phase distribution and residual stress in ferritic steel weldments. Acta Mater 75:1–19. https://doi.org/10.1016/j.actamat.2014.04.045
Hemmesi K, Farajian M, Boin M (2017) Numerical studies of welding residual stresses in tubular joints and experimental validations by means of x-ray and neutron diffraction analysis. Mater Des 126:339–350. https://doi.org/10.1016/j.matdes.2017.03.088
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interest.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Recommended for publication by Commission XIII—Fatigue of Welded Components and Structures
Rights and permissions
About this article
Cite this article
Sarmast, A., Schubnell, J. & Farajian, M. Finite element simulation of multi-layer repair welding and experimental investigation of the residual stress fields in steel welded components. Weld World 66, 1275–1290 (2022). https://doi.org/10.1007/s40194-022-01286-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40194-022-01286-5