Skip to main content
SpringerLink
Log in

Residual stresses due to gas arc welding of aluminum alloy joints by numerical simulations

  • Original Research
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

This study deals with the numerical simulation of the gas arc welding process of Aluminum tee joints using finite element analysis and evaluation of the effect of welding parameters on residual stress build up. The 3D simulations are performed using ABAQUS code for thermo-mechanical analyses with moving heat source, material deposition, solid-liquid phase transition, temperature dependent material properties, metal elasticity and plasticity, and transient heat transfer. Quasi Newton method is used for the analysis routine and thermo-mechanical coupling is assumed; i.e. the thermal analysis is completed before performing a separate mechanical analysis based on the thermal history. The residual stress build up and temperature history state in a three-dimensional analysis of the tee joint is then compared to experimental results. Hole drilling method is used for measuring the residual stress, while temperature history is measured by thermocouples. After carrying out numerical simulations, the effects of voltage/current, welding speed, material thickness and size of electrode on residual stress build-up and resulting distortions are evaluated.

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
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25

Similar content being viewed by others

References

  1. Zhang J, Dong P, Brust F (1999) Residual stress analysis and fracture assessment of weld joints in moment frames. ASME PVP—Fracture, Fatigue and Weld Residual Stress. 393 201–207

  2. Preston R, Smith S, Shercliff H, Withers P (1999) An investigation into the residual stresses in an aluminum 2024 test weld. ASME PVP—Fracture, Fatigue and Weld Residual Stress. 393 265–277

  3. Dong P, Hong J, Bynum J, Rogers P (1997) Analysis of residual stresses in Al-Li alloy repair welds. ASME PVP—Approximate Methods in the Design and Analysis of Pressure Vessels and Piping Components. 347 61–75

  4. Karlsson RI, Josefson BL (1990) Three-dimensional finite element analysis of temperatures and stresses in a single-pass butt-welded pipe. ASME Journal of Pressure Vessel Technology 112:76–84

    Article  Google Scholar 

  5. Chao Y, Qi X (1999) Thermo-mechanical modeling of residual stress and distortion during welding process. ASME PVP—Fracture, Fatigue and Weld Residual Stress. 393 209–213

  6. Oddy A, Goldak S, McDill JA (1989) Transformation plasticity and residual stresses in single-pass repair welds. ASME PVP—Weld Residual Stresses and Plastic Deformation. 173 13–18

  7. Michaleris P, Feng Z, Campbell G (1997) Evaluation of 2D and 3D FEA models for predicting residual stress and distortion. ASME PVP—Approximate Methods in the Design and Analysis of Pressure Vessels and Piping Components. 347 91–102

  8. Michaleris P, Dantzig J, Tortorelli D (1999) Minimization of welding residual stress and distortion in large structures. Welding Journal. Welding Research Supplement 361–366

  9. Tsai CL, Park SC, Cheng WT (1999) Welding distortion of a thin-plate panel structure. Welding Journal, Welding Research Supplement 156–165

  10. McDill JMJ, Oddy AS, Goldak JA (1993) Comparing 2-D plane strain and 3-D analyses of residual stresses in welds. International Trends in Welding Science and Technology, Proceedings of the 3rd International Conference on Trends in Welding Research, ASM International, Materials Park, OH. pp 105–108

  11. Hong JK, Tsai CL, Dong P (1998) Assessment of numerical procedures for residual stress analysis of multipass welds. Welding Journal, Welding Research Supplement, pp 372–382

  12. Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metallurgical Transactions B, pp 299–305

  13. Junek L, Slovacek M, Magula V, Ochodek V (1999) Residual stress simulation incorporating weld HAZ microstructure. ASME PVP—Fracture, Fatigue and Weld Residual Stress, pp 179–192

  14. Vincent Y, Jullien JF, Cavallo N, Taleb L, Cano V, Taheri S, Gilles Ph (1999) On the validation of the models related to the prevision of the HAZ behaviour. ASME PVP Fracture, Fatigue and Weld Residual Stress, pp 193–200

  15. Brown S, Song H (1992) Finite element simulation of welding of large structures. ASME Journal of Engineering for Industry, pp 441–451

  16. Dubois D, Devaux J, Leblond JB (1984) Numerical simulation of a welding operation: calculation of residual stresses and hydrogen diffusion. ASME Fifth International Conference on Pressure Vessel Technology, Materials and Manufacturing, San Francisco, pp 1210–1238

  17. Goldak J, Gu M (1995) Computational weld mechanics of the steady state. Mathematical modelling of weld phenomena 2, The Institute of Materials, London, 207–5

  18. Oddy AS, McDill JMJ, Goldak JA (1990) Consistent strain fields in 3D finite element analysis of welds. ASME Journal of Pressure Vessel Technology, Technical Briefs, pp 309–311

  19. Dong P, Ghadiali PN, Brust FW (1998) Residual stress analysis of a multi-pass girth weld. ASME PVP—Fatigue, Fracture, and Residual Stresses, pp 421–431

  20. Feng Z, Wang XL, Spooner S, Goodwin GM, Maziasz PJ, Hubbard CR, Zacharia T (1996) A finite element model for residual stress in repair welds. ASME PVPResidual Stresses in Design, Fabrication, Assessment and Repair, pp 119–125

  21. Karlsson L, Jonsson M, Lindgren LE, Nasstrom M, Troive L (1989) Residual stresses and deformations in a welded thin-walled pipe. ASME PVP—Weld Residual Stress and Plastic Deformation, pp 7–10

  22. Grong O, Myhr OR (1993) Modelling of the strength distribution in the heat affected zone of 6082-T6 aluminum weldments. Mathematical Modelling of Weld Phenomena, The Institute of Materials, London, pp 300–311

  23. ESI Group, 2000, SYSTUS 2000 Analysis reference manuals, ESI North America, 13399 West Star, Shelby Township, MI

  24. Chan B, Pacey J, Bibby M (1999) Modeling gas metal arc weld geometry using artificial neural network technology. Can Metall Quart, pp 43–51

  25. Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metallurgical Transactions B, pp 299–305

  26. Goldak J, Chakravarti A, Bibby M (1985) A double ellipsoidal finite element model for welding heat sources. In: IIW Doc. No. 212-603-85

  27. Rybicki EF, McGuire PA, Merrick E, Wert J (1982) The effect of pipe thickness on residual stresses due to girth welds. ASME Journal of Pressure Vessel Technology, pp 204

  28. Fricke S, Keim E, Schmidt J (2001) Numerical weld modeling-a method for calculating weld-induced residual stresses. Nucl Eng Des 206:139–150

    Article  Google Scholar 

  29. Michaleris P, Feng Z, Campbell G (1997) Evaluation of 2D and 3D FEA models for predicting residual stress and distortion. ASME PVP—Approximate Methods in the Design and Analysis of Pressure Vessels and Piping Components, 347, pp 91–102

  30. Callister W (1995) Materials science and engineering. John Wiley & Sons, Inc., NewYork, NY, pp.236–243, 142, 558, 560

  31. ESI Group (2000) SYSTUS 2000 analysis reference manuals, ESI North America, 13399 West Star, Shelby Township, MI

  32. Masubuchi K (1980) Analysis of welded structures-residual stresse, distortion, and their consequence. Pergamon, New York, p 205

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Iran University of Science & Technology, Narmak, 16846, Tehran, Iran

    M. Ahmadzadeh & B. Farshi

  2. Department of Marine Structures, Iran Air Naval Research Center, Chamran, 7194915685, Shiraz, Iran

    H. R. Salimi & A. Hoseini Fard

Authors
  1. M. Ahmadzadeh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. B. Farshi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. R. Salimi
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. A. Hoseini Fard
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. Ahmadzadeh.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Ahmadzadeh, M., Farshi, B., Salimi, H.R. et al. Residual stresses due to gas arc welding of aluminum alloy joints by numerical simulations. Int J Mater Form 6, 233–247 (2013). https://doi.org/10.1007/s12289-011-1081-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12289-011-1081-4

Keywords

Search

Navigation