Analysis of Residual Stresses and Angular Distortion in Stiffened Cylindrical Shell Fillet Welds Using Finite Element Method
In this paper, a two-dimensional method is developed to simulate the fillet welds in a stiffened cylindrical shell, using finite element method. The stiffener material is aluminum 2519. The thermo-elasto-plastic analysis is used to analyze the thermo-mechanical behavior. Due to the high heat flux rate of the welding process, two uncouple thermal and mechanical analysis are carried out instead of performing a single couple thermo-mechanical simulation. In order to investigate the effects of the welding procedures, two different welding techniques are examined. The resulted residual stresses and distortions due to different welding procedures are obtained. Furthermore, this study employed the technique of element birth and death to simulate the weld filler variation with time in fillet welds. The obtained results are in good agreement with the published experimental and three-dimensional numerical simulation results. Therefore, the proposed 2D modeling technique can effectively give the corresponding results of 3D models. Furthermore, by inspection of the obtained residual hoop and transverse stresses and angular distortions, proper welding procedure is suggested.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1124649Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1353
 Teng T.L., Fung C.P., Chang P.H. Yang W.C., Analysis of residual stresses and distortions in T-joint fillet welds, J. of int. pressure vessels and piping 78: 523-538, 2001.
 Perić M., Tonkovic´ Z., Rodic´ A., Surjak M., Garašic´ I., I. Boras A. Švaic´ S., Numerical analysis and experimental investigation of welding residual stresses and distortions in a T-joint fillet weld, Mat. & Des.; 53: 1052–1063, 2014.
 D. Deng W.L., H. Murakawa, Determination of welding deformation in fillet-welded joint by means of numerical simulation and comparison with experimental measurements, J. Mater. Process. Technol.; 183(2–3): 219–225, 2007.
 Watanabe M. Satoh K., Effect of welding condition on the shrinkage distortion in welded structures, Weld. J., Weld. Res. Suppl.: 337-384, 1961.
 White J.D., Leggatt R.H. Dwight J.B., Weld shrinkage prediction, Weld. Met. Fabrication: 587–596, 1980.
 Satoh K. Terasaki T., Effect of welding condition on welding deformation in welded structural materials, J. Jpn. Weld. Soc.; 45(4): 302–308, 1976.
 Shibahara M. Murakawa H., Effect of various factors on transverse shrinkage under butt welding, Trans. JWRI; 27 (2): 97–106, 1998.
 Tsirkas S.A., Papanikos P. Kermanidis T., Numerical simulation of the laser welding process in butt-joint specimens, J. Mater. Process. Technol.; 134(1): 59–69, 2003.
 Verhaeghe G., Predictive Formulate for Weld Distortion—A Critical Review, Abington Publishing, Cambridge, England: 1999.
 Boyles L.G., Computer Analysis of Failure Modes in Welded Joints, ASME PVPWeld Residual Stress and Plastic Deformation; 173: 1-4, 1989.
 Lee C. Chang K., Three-dimensional finite element simulation of residual stresses in circumferential welds of steel pipe diameter effects, Mater Sci Eng A; 487(21): 0-8, 2008.
 Deng D., FEM prediction of welding residual stress and distortion in carbonsteel considering phase transformation effects, Mat. & Des.; 30(5): 59-66, 2009.
 Gannon L., Liu Y., Pegg N. Smith M., Effect of welding sequence on residual stressand distortion in flat-bar stiffened plates, Mar. Struct.; 23: 385–404, 2010.
 Long H., Gery D., Carlier A. Maropoulos P.G., Prediction of welding distortion inbutt joint of thin plates, Mat. & Des.; 30(41): 26–35, 2009.
 Chang P.H..Teng T.L., Numerical and experimental investigation on the residual stress of the butt-welded joints, J. of Comp. Mat. Sci.; 29: 511-522, 2004.
 Bonifaz E.A., Finite Element Analysis of Heat Flow in Single-Pass Arc Welds, Weld. J., Weld. res. Supp.; 125: 2003.
 Preston R., Smith S., Shercliff H. Withers P., An Investigation into the Residual Stresses in an Aluminum 2024 Test Weld, ASME PVP- Fracture, Fatigue and Weld Residual Stress; 393: 265-277, 1999.
 Dong P., Hong J., Bynum J. Rogers P., Analysis of Residual Stresses in Al-Li Alloy Repair Welds, ASME PVP- Approximate Methods in the Design and Analysis of Pressure: 1997.
 Hong J.K., Tsai C.L. Dong P., Assessment of Numerical Procedures for Residual Stress Analysis of Multipass Welds, Weld. J., Weld. Res. Suppl.: 372- 382, 1998.
 Brown S. Song H., Finite Element Simulation of Welding of Large Structures, ASME Journal of Engineering for Industry; 114: 441-451, 1992.
 Dong P., Ghadiali P.N..Brust F.W., Residual Stress Analysis of a Multi-Pass Girth Weld, ASME PVP- Fatigue, Fracture, and Residual Stresses; 373: 421-431, 1998.
 Karlsson R.I..Josefson B.L., 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, 1990.
 Al. Y.V.E., On the Validation of the Models Related to the Prevision of the HAZ Behaviour, ASME PVP Fracture, Fatigue and Weld Residual Stress; 393: 193-200, 1999.
 Dubois D., Devaux J. Leblond J.B., Numerical Simulation of a Welding Operation: Calculation of Residual Stresses and Hydrogen Diffusion, ASME Fifth International Conference on Pressure Vessel Technology, Materials and Manufacturing; 2: 1210 - 1238., 1984.
 Junek L., Slovacek M., Magula V. Ochodek V., Residual Stress Simulation Incorporating Weld HAZ Microstructure, ASME PVP- Fracture, Fatigue and Weld Residual Stress; 393: 179-192, 1999.
 Michaleris P. Debicciari A., Prediction of welding distortion, Weld. J., Weld. Res. Suppl.; 76(4): 172-180, 1997.
 Deo M.V., Michaleris P. Sun J., Prediction of buckling distortion of welded structures, Sci. Technol. Weld. Join.; 8: 55-61, 2003.
 Barsoum Z. Lundbäck A., Simplified FE welding simulation of fillet welds - 3D effects on the formation residual stresses, Eng. Fail. Analysis; 16(7): 2281-2289, 2009.
 Pilipenko A., Computer simulation of residual stress and distortion of thick plates in multi-electrode submerged arc welding, Doctoral Thesis,: 2001.
 Shim Y., Feng Z., Lee S., Kim D., Jaeger J., Papitan J.C. C.L. Tsai, Determination of Residual Stress in Thick-Section Weldments, Weld. J., Weld. Res. Suppl.: 305-312, 1992.
 Oddy A.S., Goldak J.A..McDill J.M.J., Transformation Plasticity and Residual Stresses in Single-Pass Repair Welds, ASME PVP- Weld Residual Stresses and Plastic Deformation; 173: 13-18, 1989.
 Oddy A.S., McDill J.M.J..Goldak J.A., Consistent strain fields in 3D FE analysis of Welds, ASME Journal of Pressure Vessel Technology; 112: 309-311, 1990.
 Chang K. Lee C., Finite element analysis of the residual stresses in T-joint fillet welds made of similar and dissimilar steels, Int. J. Adv. Manuf. Technol.; 41(250): 2009.
 Vakili-Tahami F. Ziaei-Asl A., Numerical and experimental investigation of T-shape fillet welding of AISI 304 stainless steel plates, Mat. & Des.; 47: 615-623, 2013.
 Goldak J., Chakravarti A. Bibby M.A., New finite element model for heat sources, Metall Trans B; 15: 299-305, 1984.
 Karlsson L., Jonsson M., Lindgren L.E., Nasstrom M. Troive L., Residual Stresses and Deformations in a Welded Thin-walled Pipe, ASME PVP- Weld Residual Stress and Plastic Deformation; 173: 7-10, 1989.
 Michaleris P., Dantzig J.D. Tortorelli, Minimization of Welding Residual Stress and Distortion in Large Structures, Weld. J., Weld. Res. Suppl.: 361-366, 1999.
 Chao Y. Qi X., Thermo-mechanical Modeling of Residual Stress and Distortion During Welding Process, ASME PVP- Fracture, Fatigue and Weld Residual Stress; 393: 209-213, 1999.
 Zaeem M.A., Nami M.R. Kadivar M.H., Prediction of welding buckling distortion in a thin wall aluminum T join, Comp. Mat. Sci.; 38(4): 588-594, 2007.
 Francis J.D., Welding Simulations of Aluminum Alloy Joints by Finite Element Analysis, Virginia Polytechnic University; M.Sc.: 2002.
 Michaleris P., Feng Z. Campbell G., 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, 1997.
 Francis J.D., Welding Simulations of Aluminum Alloy Joints by Finite Element Analysis, M.Sc.: 2002.