Skip to main content
SpringerLink
Log in

3D finite element simulation of temperature distribution, residual stress and distortion on 304 stainless steel plates using GTA welding

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

In the present study, the distortion induced in rectangular plate of AISI 304 SS during autogenous GTA welding process is measured experimentally and further validated using Finite element (FE) analysis. The thermal histories are measured at fixed locations over the surface of the plate and the results are compared with FE analysis. The Gaussian surface and Volumetric heat source models are simulated and transient heat transfer analysis is performed. The heat source models have been tested with two different speeds. The effectiveness of change in thermal histories of the heat sources have been studied and reported. In FE analysis, the sequentially coupled thermomechanical analysis is performed using the thermal histories as input and the distortion of the plates are predicted and compared with experimental measurements. The large and small displacement theories are employed for the above purpose and the effectiveness of the theories are reported. The edge deformation of the plates have been measured and validated for both the theories. The residual stress and distortion at the mid span are predicted and discussed. The results predicted using large displacement theory is in good agreement with measured values.

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

Similar content being viewed by others

References

  1. C.-H. Lee and K.-H. Chang, Temperature fields and residual stress distributions in dissimilar steel butt welds between carbon and stainless steels, Applied Thermal Engineering, 45-46 (2012) 33–41.

    Article  Google Scholar 

  2. Z. Barsoum and A. Lundbäck, Simplified FE welding simulation of fillet welds -3D effects on the formation residual stresses, Engineering Failure Analysis, 16 (2009) 2281–2289.

    Article  Google Scholar 

  3. M. M. Mahapatra, G. L. Datta, B. Pradhan and N. R, Mandal, Three-dimensional finite element analysis to predict the effects of SAW process parameters on temperature distribution and angular distortions in single-pass butt joints with top and bottom reinforcements, International Journal of Pressure Vessels and Piping, 83 (2006) 721–729.

    Google Scholar 

  4. D. Deng, W. Liang and H. Murakawa, Determination of welding deformation in fillet-welded joint by means of numerical simulation and comparison with experimental measurements, Journal of Materials Processing Technology, 183 (2007) 219–225.

    Article  Google Scholar 

  5. A. Chaudhri, M. Parang and B. E. Nelson, Computer simulation and experimental verification of welding in thin steel sheet containment, International Journal of Heat and Mass Transfer, 50 (2007) 4439–4445.

    Article  MATH  Google Scholar 

  6. I. Sattari-Far and Y. Javadi, Influence of welding sequence on welding distortions in pipes, International Journal of Pressure Vessels and Piping, 85 (2008) 265–74.

    Article  Google Scholar 

  7. V. Pavelic, R. Tanbakuchi, O. A. Uyehara and P. S. Myers, Experimental and computed temperature histories in gas tungsten-arc welding of thin plates, Weld. J., 48 (1969) 295 s-305s.

    Google Scholar 

  8. E. Friedman, Thermo mechanical analysis of the welding process using the finite element method, J. Press. Vess. Technol., 97 (3) (2010) 206–213.

    Article  Google Scholar 

  9. S. A. A. A. Mousavi and R. Miresmaeili, Experimental and numerical analyses of residual stress distributions in TIG welding process for 304L stainless steel, Journal of Materials Processing Technology, 208 (2008) 383–394.

    Article  Google Scholar 

  10. A. Kermanpur, M. Shamanian and V. E. Yeganeh, Threedimensional thermal simulation and experimental investigation of GTAW circumferentially butt-welded Incoloy 800 pipes, Journal of Materials Processing Technology, 199 (2008) 295–303.

    Article  Google Scholar 

  11. F. Vakili-Tahami and A. Ziaei-Asl, Numerical and experimental investigation of T-shape fillet welding of AISI 304 stainless steel plates, Materials and Design, 47 (2013) 615–623.

    Article  Google Scholar 

  12. A. Yaghi, T. H. Hyde, A. A. Becker, W. Sun and J. A. Williams, Residual stress simulation in thin and thick-walled stainless steel pipe welds including pipe diameter effects, International Journal of Pressure Vessels and Piping, 83 (2006) 864–874.

    Article  Google Scholar 

  13. D. Deng, Y. Zhou, T. Bi and X. Liu, Experimental and numerical investigations of welding distortion induced by CO2 gas arc welding in thin-plate bead-on joints, Materials and Design, 52 (2013) 720–729.

    Article  Google Scholar 

  14. H. M. Asl and A. Vatani, Numerical analysis of the burnthrough at in-service welding of 316 stainless steel pipeline, International Journal of Pressure Vessels and Piping, 105-106 (2013) 49–59.

    Article  Google Scholar 

  15. M. Peric, Z. Tonkovic, A. Rodic, M. Surjak, I. Garašic´, I. Boras and S. Švaic´, Numerical analysis and experimental investigation of welding residual stresses and distortions in a T-joint fillet weld, Materials and Design, 53 (2014) 1052–63.

    Article  Google Scholar 

  16. I. Sattari-Far and M. R. Farahani, Effect of the weld groove shape and pass number on residual stresses in butt-welded pipes, International Journal of Pressure Vessels and Piping, 86 (2009) 723–731.

    Article  Google Scholar 

  17. H. Purmohamad, A. Kermanpur and M. Shamanian, Numerical simulation and experimental investigation of temperature distribution in the circumferentially butt GTAW of Incoloy 800H pipes, International Journal of Pressure Vessels and Piping, 87 (2010) 424–432.

    Article  Google Scholar 

  18. D. Deng and H. Murakawa, Prediction of welding distortion and residual stress in a thin plate butt-welded joint, Computational Materials Science, 43 (2008) 353–365.

    Article  Google Scholar 

  19. M. Zubairuddin, S. K. Albert, S. Mahadevan, M. Vasudevan, V. Chaudhari and V. K. Suri, Experimental and finite element analysis of residual stress and distortion in GTAwelding of modified 9Cr-1Mo steel, Journal of Mechanical Science and Technology, 28 (12) (2014) 5095–5105.

    Article  Google Scholar 

  20. H. Moein and I. Sattari-Far, Different finite element techniques to predict welding residual stresses in aluminum alloy plates, Journal of Mechanical Science and Technology, 28 (2) (2014) 679–689.

    Article  Google Scholar 

  21. B.-Q. Chen, M. Hashemzadeh and C. G. Soares, Numerical and experimental studies on temperature and distortion patterns in butt-welded plates, International Journal of Advanced Manufacturing Technology, 72 (2014) 1121–1131.

    Article  Google Scholar 

  22. C. Wang, Y.-R. Kim and J.-W. Kim, Comparison of FE Models to predict the welding distortion in T-joint gas metal arc welding process, International Journal of Precision Engineering and Manufacturing, 15 (8) (2014) 1631–1637.

    Article  Google Scholar 

  23. M. Adak and C. G. Soares, Effects of different restraints on the weld-induced residual deformations and stresses in a steel plate, International Journal of Advanced Manufacturing Technology, 71 (2014) 699–710.

    Article  Google Scholar 

  24. R. Keivani, M. Jahazi, T. Pham, A. R. Khodabandeh and M. R. Afshar, Predicting residual stresses and distortion during multi sequence welding of large size structures using FEM, International Journal of Advanced Manufacturing Technology, 73 (2014) 409–419.

    Article  Google Scholar 

  25. M. Hashemzadeh, B. Q. Chen and C. Guedes Soares, Numerical and experimental study on butt weld with dissimilar thickness of thin stainless steel plate, International Journal of Advanced Manufacturing Technology, 78 (2015) 319–330.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Engineering College, K.R. Nagar, Tamilnadu, Kovilpatti, 628 503, India

    D. Venkatkumar & D. Ravindran

Authors
  1. D. Venkatkumar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. D. Ravindran
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to D. Venkatkumar.

Additional information

D. Venkatkumar completed B.E. and M.E. from Madurai Kamaraj University in 1999 and 2002, respectively. He is doing Ph.D. in Anna University and also working as an Assistant Professor in National Engineering College, India. His current research includes modeling and finite element simulation of temperature distribution, residual stresses and distortion of welding process.

D. Ravindran is a Professor in the Department of Mechanical Engineering at National Engineering College, India. He received his Ph.D. degree in Manufacturing Engineering from Manonmaniam Sundaranar University, India in 2005. He has published 22 papers in peer reviewed journals. His research area includes Scheduling Optimization, Natural fiber composites, Diffusion bonding and Material characterization.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Venkatkumar, D., Ravindran, D. 3D finite element simulation of temperature distribution, residual stress and distortion on 304 stainless steel plates using GTA welding. J Mech Sci Technol 30, 67–76 (2016). https://doi.org/10.1007/s12206-015-1208-5

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-015-1208-5

Keywords

Search

Navigation