Investigations on Transient Temperature Distribution and Distortion in Shielded Metal Arc Welding of SA 516 Gr. 70 Steel

Jump To References Section

Authors

  • ISGEC Hitachi Zosen Limited, Dahej – 392130, Gujarat ,IN
  • Advanced Welding Laboratory, Department of Mechanical Engineering S. V. National Institute of Technology, Surat – 395007, Gujarat ,IN
  • Advanced Welding Laboratory, Department of Mechanical Engineering S. V. National Institute of Technology, Surat – 395007, Gujarat ,IN
  • Advanced Welding Laboratory, Department of Mechanical Engineering S. V. National Institute of Technology, Surat – 395007, Gujarat ,IN

DOI:

https://doi.org/10.22486/iwj.v57i1.223728

Keywords:

SMAW process, Simulation, Thermal analysis, Structural analysis, Goldak's heat source, Welding distortion, SA516 Grade-70 steel.

Abstract

Efforts are made in this article to investigate the thermal and mechanical phenomena by presenting a coupled thermal and structural analysis of SA516 Grade-70 steel. This material has wide applicability in the fabrication of pressure vessels, boilers, etc., due to its excellent weldability and formability. An actual ongoing problem from a reputed industry, related to distortion during the shielded metal arc welding process, is considered and experiments are carried out on the chosen steel. Results are evaluated employing a two- step methodology, involving simulation. The first step encompasses thermal analysis, providing insights into transient temperature distribution, while the subsequent mechanical analysis offers data on residual stresses and distortion. In the case of heat input, a volumetric heat source with double ellipsoidal heat distribution is used whereas a plasticity material model with rate-independent bilinear kinematic hardening is adopted for the structural analysis. Additionally, temperature-dependent material properties are factored into both scenarios. The data derived from numerical analysis align closely with experimental findings, presenting valuable insights for fabricating industries.

Downloads

Published

2024-05-23

Issue

Section

Research Articles

 

References

Lindgren LE (2007); Computational welding mechanics, Woodhead Publishing, Cambridge.

Attarha MJ and Sattari FI (2011); Study on welding temperature distribution in thin welded plates through experimental measurements and finite element simulation, Journal of Materials Processing Technology, 211(4), pp.688-694.

Panwala MSM, Channiwala SA and Shrinivasan KN (2009); Numerical simulation of transient temperature in SMAW, Proceedings of the ASME 2009 Pressure Vessel and Piping Conference, Prague, Czech Republic, pp.449-456.

do Carmo DA and de Faria AR (2015); A 2D finite element with through the thickness parabolic temperature distribution for heat transfer simulations including welding, Finite Elements in Analysis and Design, 93(1), pp.85-95.

Mahapatra MM, Datta GL, Pradhan B and Mandal NR (2006); Three-dimensional finite element analysis to predict the effects of SAW process parameters on temperature distribution and angular distortions in single-pass butt joints with top and bottom reinforcements, International Journal of Pressure Vessels and Piping, 83(10), pp.721-729.

Mollicone P, Camilleri D, Gray TG and Comlekci T (2006); Simple thermo-elastic–plastic models for welding distortion simulation, Journal of Materials Processing Technology, 176(1-3) pp.77-86.

Goldak J, Chakravarti A and Bibby M (1984); A new finite-element model for welding heat-sources, Metallurgical Transaction B, 15(2), pp.299-305.

Anca A, Cardona A, Risso J and Fachinotti VD (2011); Finite element modeling of welding processes, Applied Mathematical Modelling, 35(2), pp.688-707.

Shan X, Davies CM, Wangsdan T, O'Dowd NP and Nikbin KM (2009); Thermo-mechanical modelling of a single- bead-on-plate weld using the finite element method, International Journal of Pressure Vessels and Piping, 86(1), pp.110-121.

Slovacek M, Divis V, Junek L and Ochodek V (2005); Numerical simulation of the welding process - distortion and residual stress prediction, heat source model determination, Welding in the World, 49(11-12), pp.15- 29.

Barroso A, Canas J, Picon R, Paris F, Mendez C and Unanue I (2010); Prediction of welding residual stresses and displacements by simplified models. Experimental validation, Materials & Design, 31(3), pp.1338-1349.

JiaX,XuJ,LiuZ,HuangS,FanYandSunZ(2014);A new method to estimate heat source parameters in gas metal arc welding simulation process, Fusion Engineering and Design, 89(1), pp.40-48.

Bhatti AA, Barsoum Z, Murakawa H and Barsoum I (2015); Influence of thermo-mechanical material properties of different steel grades on welding residual stresses and angular distortion, Materials & Design, 65(1), pp.878-889.

Yadav A, Ghosh A and Kumar A (2017); Experimental and numerical study of thermal field and weld bead characteristics in submerged arc welded plate, Journal of Materials Processing Technology, 248(1), pp.262- 274.

Ghosh A, Chattopadhyaya S and Hloch S (2012); Prediction of weld bead parameters, transient temperature distribution and HAZ width of submerged arc welded structural steel plates, TehnickiVjesnik, 19(3), pp.617-620.

Negi V and Chattopadhyaya S (2013); Critical assessment of temperature distribution in submerged arc welding process, Advances in Materials Science and Engineering, 2013(1), pp.1-9.

Chang PH and Teng TL (2004); Numerical and experimental investigations on the residual stresses of the butt-welded joints, Computational Materials Science, 29(4), pp.511-522.

Deng D and Murakawa H (2008); Prediction of welding distortion and residual stress in a thin plate butt-welded joint, Computational Materials Science, 43(2), pp.353- 365.

Zhu XK and Chao YJ (2002); Effect of temperature dependent material properties on welding simulation, Computers & Structures, 80(11), pp.967-976.

Teng TL, Chan PH and Tseng WC (2003); Effect of welding sequences on residual stresses, Computers & Structures, 81(5), pp.273-286.

Li C and Wang Y (2013); Three-dimensional finite element analysis of temperature and stress distributions for in-service welding process, Materials & Design, 52(1), pp.1052-1057.

Islam M, Buijk A, Rais-Rohani M and Motoyama K (2014);Simulation-based numerical optimization of arc welding process for reduced distortion in welded structures,Finite Elements in Analysis and Design, 84(1), pp.54-64.

Xia J and Jin H (2017); Numerical study of welding simulation and residual stress on butt welding of dissimilar thickness of austenitic stainless steel, The International Journal of Advanced Manufacturing Technology, 91(1-4), pp.227–235.

Pu X, Zhang C, Li S and Deng D (2017); Simulating welding residual stress and deformation in a multi-pass butt-welded joint considering balance between computing time and prediction accuracy, The International Journal of Advanced Manufacturing Technology,93(5-8), pp.2215–2226.

Wei L, Geng X and Du A (2018);Theoretical analysis and experimental study on heat transfer mechanism and thermal insulation properties of composite insulation coating, International Journal of Simulation and Process Modelling, 13(3), pp.272-280.

Kalyankar VD and Pujari A (2018);Simulation and design optimisation of broach tool geometry for enhancing material removal rate, International Journal of Simulation and Process Modelling, 13(3), pp.264- 271.

Dar NU, Qureshi EM and Hammouda MMI (2009); Analysis of weld-induced residual stresses and distortions in thin-walled cylinders, Journal of Mechanical Science and Technology, 23(4), pp.1118- 1131.

Karlsson RI and Josefson BL (1990); Three-dimensional finite element analysis of temperature and stress in single-pass butt-welded pipe, Journal of Pressure Vessel Technology, 112(1), pp.76-84.

Brown SB and Song H (1992); Implications of three- dimensional numerical simulations of welding of large structures, Welding Journal, 71(2), pp.55-62.