Numerical Modeling of Multi-Pass Arc Welding Processes: Integration with Experimental Validation for Distortion analysis and Characterization

Abstract

The increasing significance of numerical simulations in the welding industry arises from their capacity to improve manufacturing conditions, ensuring greater effectiveness and precision. The utilization of the finite element method (FEM) enables comprehensive and focused calculations of mechanical and material structural alterations induced by the welding process. Acquiring knowledge of these parameters not only serves to augment the quality of the manufacturing process but also yields consequential benefits, such as reducing adverse effects like base plate distortion. Consequently, enhancing structural performance and prolonging lifespan becomes achievable, aligning with overarching sustainability goals. To accomplish this objective, this paper involves the numerical simulation of a welding process based on experimental tests, with a focus on investigating the deformations caused by the heat generated during welding as the primary parameter of interest. Advanced modeling techniques are employed to assess the results as part of a comprehensive thermo-mechanical analysis framework, examining and characterizing the impact of the temperature distribution. In the finite element analysis (FEA), a total of 12 welding cycles were systematically modeled to align with experimental conditions, incorporating cooling intervals and preheating considerations. The outcomes of this research exemplify the potential of numerical simulation in the welding industry, demonstrating a diverse range of results achieved through FEA to enhance the quality of structures.