Skip to main content
SpringerLink
Log in

Study of Welding Distortion and Residual Stress Considering Nonlinear Yield Stress Curves and Multi-constraint Equations

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Inherent strain analysis has been successfully applied to predict welding deformations of large-scale structural components, while thermal-elastic-plastic finite element method is rarely used for its disadvantages of long calculation period and large storage space. In this paper, a hybrid model considering nonlinear yield stress curves and multi-constraint equations to thermal-elastic-plastic analysis is further proposed to predict welding distortions and residual stresses of large-scale structures. For welding T-joint structural steel S355JR by metal active gas welding, the published experiment results of temperature and displacement fields are applied to illustrate the credibility of the proposed integration model. By comparing numerical results of four different cases with the experiment results, it is verified that prediction precision of welding deformations and residual stresses is apparently improved considering the power-law hardening model, and computational time is also obviously shortened about 30.14% using multi-constraint equations. On the whole, the proposed hybrid method can be further used to precisely and efficiently predict welding deformations and residual stresses of large-scale structures.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. O.T. Ola and F.E. Doern, Fusion Weld Ability Studies in Aerospace AA7075-T651 Using High-Power Continuous Wave Laser Beam Techniques, Mater. Des., 2015, 77, p 50–58

    Article  Google Scholar 

  2. J. Adamus and P. Lacki, Analysis of Forming Titanium Welded Blanks, Comput. Mater. Sci., 2014, 94, p 66–72

    Article  Google Scholar 

  3. W. Liu, J.J. Ma, M.M. Atabaki, and R. Kovacevic, Joining of Advanced High-Strength Steel to AA 6061 Alloy by Using Fe/Al Structural Transition Joint, Mater. Des., 2015, 68, p 146–157

    Article  Google Scholar 

  4. Y.M. Rong, Z. Zhang, G.J. Zhang, C. Yue, Y.F. Gu, Y. Huang, C.M. Wang, and X.Y. Shao, Parameters Optimization of Laser Brazing in Crimping Butt Using Taguchi and BPNN-GA, Opt. Laser. Eng., 2015, 67, p 94–104

    Article  Google Scholar 

  5. W.J. He, B.F. Luan, R.L. Xin, J.B. Xu, and Q. Liu, A Multi-scale Model for Description of Strain Localization in Friction Stir Welded Magnesium Alloy, Comput. Mater. Sci., 2015, 104, p 162–171

    Article  Google Scholar 

  6. D. Deng, H. Murakawa, and W. Liang, Prediction of Welding Distortion in a Curved Plate Structure by Means of Elastic Finite Element Method, J. Mater. Process. Technol., 2008, 203, p 252–266

    Article  Google Scholar 

  7. Y. Ueda, Y.C. Kim, and M.G. Yuan, A Predicting Method of Welding Residual Stress Using Source of Residual Stress (Report I), Trans. JWRI, 1989, 18(2), p 135–141

    Google Scholar 

  8. Y. Ueda and M.G. Yuan, Prediction of Residual Stresses in Butt-Welded Plates Using Inherent Strains, J. Mater. Process. Technol., 1993, 115(8), p 417–423

    Article  Google Scholar 

  9. M.G. Yuan and Y. Ueda, Prediction of Residual Stresses in Welded T- and I-Joints Using Inherent Strains, J. Eng. Mater. Technol., 1996, 118(4), p 229–234

    Article  Google Scholar 

  10. J.C. Wang, S. Rashed, H. Murakaw, and Y. Luo, Numerical Prediction and Mitigation of Out-of-Plane Welding Distortion in Ship Panel Structure by Elastic FE Analysis, Mar. Struct., 2013, 34, p 135–155

    Article  Google Scholar 

  11. H.S. Mun and S.I. Seo, Welding Strain Analysis of Friction Stir-Welded Aluminum Alloy Structures Using Inherent Strain-Based Equivalent Loads, J. Mech. Sci. Technol., 2013, 27(9), p 2775–2782

    Article  Google Scholar 

  12. J.J. Xu, L.G. Chen, J.H. Wang, and C.Z. Ni, Prediction of Welding Distortion in Multipass Girth-Butt Welded Pipes of Different Wall Thickness, Int. J. Adv. Manuf. Technol., 2008, 35, p 987–993

    Article  Google Scholar 

  13. P. Biswas, N.R. Mandal, and S. Das, Prediction of Welding Deformations of Large Stiffened Panels Using Average Plastic Strain Method, Sci. Technol. Weld. Join., 2011, 16(3), p 227–231

    Article  Google Scholar 

  14. D. Deng, H. Murakawa, and N. Ma, Predicting Welding Deformation in Thin Plate Panel Structure by Means of Inherent Strain and Interface Element, Sci. Technol. Weld. Join., 2012, 17(1), p 13–21

    Article  Google Scholar 

  15. H. Murakawa, N. Ma, and H. Huang, Iterative Substructure Method Employing Concept of Inherent Strain for Large-Scale Welding Problems, Weld World, 2015, 59, p 53–63

    Article  Google Scholar 

  16. W. Liang and H. Murakawa, An Inverse Analysis Method to Estimate Inherent Deformations in Thin Plate Welded Joints, Mater. Des., 2012, 40, p 190–198

    Article  Google Scholar 

  17. Y. Ueda and T. Yamakawa, Analysis of Thermal Elastic-Plastic Stress and Strain During Welding by Finite Element Method, Trans. JWRI, 1971, 2, p 90–100

    Google Scholar 

  18. D. Deng and S. Kiyoshim, Numerical Simulation of Residual Stresses Induced by Laser Beam Welding in a SUS316 Stainless Steel Pipe with Considering Initial Residual Stress Influences, Nucl. Eng. Des., 2010, 240, p 688–696

    Article  Google Scholar 

  19. Y.Z. Li, K.Y. Wang, Y.J. Jin, M.J. Xu, and H. Lu, Prediction of Welding Deformation in Stiffened Structure by Introducing Thermo-mechanical Interface Element, J. Mater. Process. Technol., 2015, 216, p 440–446

    Article  Google Scholar 

  20. Z. Zeng, X.B. Li, Y.G. Miao, G. Wu, and Z.J. Zhao, Numerical and Experiment Analysis of Residual Stress on Magnesium Alloy and Steel Butt Joint by Hybrid Laser-TIG Welding, Comput. Mater. Sci., 2011, 50, p 1763–1769

    Article  Google Scholar 

  21. J.U. Park and H.W. Lee, Effects of Initial Condition of Steel Plate on Welding Deformation and Residual Stress Due to Welding, J. Mech. Sci. Technol., 2007, 21, p 426–435

    Article  Google Scholar 

  22. N. Ma, H. Huang, and H. Murakaw, Effect of Jig Constraint Position and Pitch on Welding Deformation, J. Mater. Process. Technol., 2015, 221, p 154–162

    Article  Google Scholar 

  23. H. Long, D. Gery, A. Carlier, and P.G. Maropoulos, Prediction of Welding Distortion in Butt Joint of Thin Plates, Mater. Des., 2009, 30, p 4126–4135

    Article  Google Scholar 

  24. J.C. Wang, M. Shibahara, X.D. Zhang, and H. Murakaw, Investigation on Twisting Distortion of Thin Plate Stiffened Structure Under Welding, J. Mater. Process. Technol., 2012, 212, p 1705–1715

    Article  Google Scholar 

  25. C. Heinze, C. Schwenk, and M. Rethmeier, Numerical Calculation of Residual Stress Development of Multi-pass Gas Metal Arc Welding, J. Constr. Steel. Res., 2012, 72, p 12–19

    Article  Google Scholar 

  26. H. Serizawa, S. Nakamura, K. Kanbe, Y. Fujita, S. Asai, and H. Murakawa, Numerical Analysis of Deformation in Multi-pass Circumferential TIG Welding with Narrow Gap, Weld World, 2013, 57, p 615–623

    Article  Google Scholar 

  27. M. Peric, D. Stamenkovic, and V. Milkovic, Comparison of Residual Stresses in Butt-Welded Plates Using Software Packages Abaqus and Ansys, Sci. Tech. Rev., 2010, 60(3–4), p 22–26

    Google Scholar 

  28. M. Peric, Z. Tonkovic, A. Rodic, M. Surjak, I. Garasic, I. Boras, and S. Svaic, Numerical Analysis and Experimental Investigation of Welding Residual Stresses and Distortions in a T-joint Fillet Weld, Mater. Des., 2014, 53, p 1052–1063

    Article  Google Scholar 

  29. M. Benedetti, V. Fontanari, and C. Santus, Crack Growth Resistance of MAG Butt-Welded Joints of S355JR Construction Steel, Eng. Fract. Mech., 2013, 108, p 305–315

    Article  Google Scholar 

  30. J. Goldak, A. Chakravarti, and M. Bibby, A New Finite Element Model for Welding Heat Sources, Metall. Trans. B, 1984, 15, p 299–305

    Article  Google Scholar 

  31. B. Brickstad and B.L. Josefson, A Parametric Study of Residual Stresses in Multi-pass Butt-Welded Stainless Steel Pipes, Int. J. Pressure Vessels Pip., 1998, 75, p 1–25

    Article  Google Scholar 

  32. W. Liu, J. Ma, S. Liu, and R. Kovacevic, Experimental and Numerical Investigation of Laser Hot Wire Welding, Int. J. Adv. Manuf. Technol., 2015, 78, p p1485–p1499

    Article  Google Scholar 

  33. W. Liu, J. Ma, F. Kong, S. Liu, and R. Kovacevic, Numerical Modeling and Experimental Verification of Residual Stress in Autogenous Laser Welding of High-Strength Steel, Lasers Manuf. Mater. Process., 2015, 2, p 24–42

    Article  Google Scholar 

  34. T.L. Teng and P.H. Chang, Three-Dimensional Thermo Mechanical Analysis of Circumferentially Welded Thin-Walled Pipes, Int. J. Pressure Vessels Pip., 1998, 75, p 237–247

    Article  Google Scholar 

  35. T. Hong, J.Y. Ooi, and B.A. Shaw, A Numerical Study of the Residual Stress Pattern from Single Shot Impacting on a Metallic Component, Adv. Eng. Softw., 2008, 39, p 743–756

    Article  Google Scholar 

  36. O. Toshinari, O. Takayoshi, and M. Fumikazu, UV Radiation Thermometry of TIG Weld Pool-Development of UV Radiation Thermometry (Report 1), Q. J. Jpn. Weld. Soc., 2004, 22(1), p 21–26

    Article  Google Scholar 

  37. Y. Rong, Y. Huang, G. Zhang, Y. Chang, and X. Shao, Prediction of Angular Distortion in No Gap Butt Joint Using BPNN and Inherent Strain Considering the Actual Bead Geometry, Int. J. Adv. Manuf. Technol. doi:10.1007/s00170-015-8102-2

Download references

Acknowledgments

This research is supported by the National Basic Research Program of China (973 Program, No. 2014CB046703) and the Fundamental Research Funds for the Central Universities (HUST, No. 2014QN016).

Author information

Authors and Affiliations

  1. State Key Lab of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Youmin Rong, Guojun Zhang & Yu Huang

Authors
  1. Youmin Rong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guojun Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yu Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yu Huang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rong, Y., Zhang, G. & Huang, Y. Study of Welding Distortion and Residual Stress Considering Nonlinear Yield Stress Curves and Multi-constraint Equations. J. of Materi Eng and Perform 25, 4484–4494 (2016). https://doi.org/10.1007/s11665-016-2259-1

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-016-2259-1

Keywords

Search

Navigation