Numerical Simulation to Study the Influence of Welding Sequence on Distortion and Residual Stresses of Butt-Welded Plates

Document Type : Original Article

Authors

1 Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Said, Egypt

2 Assistant Professor, Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Said, Egypt

3 Professor, Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Said, Egypt

Abstract

In many accurate industries such as gas turbine and aerospace, welding technique is used to weld thin parts during the assembling process. Due to uneven heating and cooling during the welding process, welded parts are prone to sever distortions and/or non-desirable residual stresses. The distortion causes problem in shape in assembly and when residual stresses combined with applied stresses, unexpected failure occurs. In this paper, three dimensional sequentially thermo-mechanical analysis is used to simulate welding process in Nical base super alloy plates (INCONEL718) for predicting the temperature field, distortion and residual stresses. The study was carried out on butt welded joint with 2 mm thickness, using the commercial Finite Element (FE) package (ABAQUS). The obtained results are compared with the numerical and experimental results obtained by other researchers. Good accordance is found between them. In order to control the distortion, it was proposed to carry out the welding process on several steps with different sequences. The cases of the welding sequences are: one step in one direction, two steps in opposite directions and four steps in two directions the study successfully predicted temperature and residual stress in the welded plates. Moreover, it was found that the more the steps of the welding process the less the distortion takes place in the plates

Keywords

Port-Said Engineering Research Journal
Volume 20, Issue 1
March 2016
Pages 118-126

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