Finite element predictions of residual stresses due to heat transfer during welding

Abstract

Finite element simulations of a single pass butt and a sequential fillet welding process are critically reviewed. Temperature history as well as welding-induced distortion and residual stress data from tests were compared to the results from the simulations for calibration and validation purposes. The main issue addressed was the sensitivity of the temperature and residual stress predictions to variations of heat input, temperature-dependent material properties as well as initial and boundary conditions. Key modelling features included an essentially 2D analysis combined with a ramped heat input function; modelling of radiation and fit-up; accounting for plastic properties variations in the welding area; the use of element death and re-birth technique to simulate sequential welding. © 2012 WIT Press.