Computers and Structures 81 (2003) 273286 www.elsevier.

com/locate/compstruc

Eect of welding sequences on residual stresses

Tso-Liang Teng a, Peng-Hsiang Chang
a b

b,*

, Wen-Cheng Tseng

University of National Defense, Chung Cheng Institute of Technology, Ta-shi, Tao-Yuan 335, Taiwan, ROC Department of Mechanical Engineering, Da-Yeh University, 112 Shan-Jiau Road, Da-Tsuen, Changhua 515, Taiwan, ROC c 455 Wing Air Force, Taiwan, ROC Received 26 March 2002; accepted 2 November 2002

Abstract Accurately predicting welding residual stresses and developing an available welding sequence for a weld system are pertinent tasks since welding residual stress is inevitably produced in a welded structure. This study analyzes the thermomechanical behavior and evaluates the residual stresses with various types of welding sequence in single-pass, multi-pass butt-welded plates and circular patch welds. This is achieved by performing thermal elasto-plastic analysis using nite element techniques. Furthermore, this investigation provides an available welding sequence to enhance the fabrication process of welded structures. 2003 Elsevier Science Ltd. All rights reserved.
Keywords: Welding sequences; Residual stresses; Butt-welded; Circular patch welds

1. Introduction Metallurgical welding joints are extensively used in the fabrication industry, including ships, oshore structures, steel bridges and pressure vessels. Among the merits of such welded structures include a high joint eciency, water and air tightness, and low fabrication cost. However, residual stresses and distortions can occur near the weld bead due to localized heating by the welding process and subsequent rapid cooling. High residual stresses in regions near the weld may promote brittle fractures, fatigue, or stress corrosion cracking. Meanwhile, residual stresses in the base plate may reduce the buckling strength of the structure members. Therefore, welding residual stresses must be minimized to control them according to the respective requirements. Previous investigators have developed several methods, including heat treatment, hammering, pre-

* Corresponding author. Tel.: +886-4-8511221; fax: +886-48511224. E-mail addresses: tlteng@mail.dyu.edu.tw, g910404@ccit. edu.tw (T.-L. Teng).

heating, vibration stress relieving, and weld sequencing to reduce the residual stresses attributed to welding. In these methods, to choose an available welding sequence is more simple and ecient for reduction welding residual stresses. Because many welded structures which cannot be post-weld manufacturing measures after welding contain residual stresses of varying degree. Therefore, developing an available welding sequence and accurately predicting welding residual stresses for welds system are necessary for achieving the safest design. For a investigation of reducing weld residual stress, Jonassen et al. [1] described the eect of welding procedures on reducing the residual stresses for butt-welded steel plates. Rybicki et al. [2,3] developed a method for reducing tensile stresses on the inner surfaces of the girth welded pipes. The process entails inductively heating the outside of a welded pipe while cooling the inner surface with owing water. Josefson [4,5] calculated the welding residual stresses that were numerically analyzed for a girth-butt welded thin-walled pipe during dierent postweld treatments. Brust and Rybick [6] developed a method called backlay welding that can be eective in producing compressive residual stresses on the pipes

0045-7949/03/$ - see front matter 2003 Elsevier Science Ltd. All rights reserved. doi:10.1016/S0045-7949(02)00447-9

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Nomenclature q C T t fqg Q g hf TB TA N fTe g C K fFe g fP g ff g fug feg density specic heat temperature time heat ux the rate of internal heat generation unit outward normal vector lm coecient bulk temperature of the adjacent uid temperature at the surface of the model element shape functions nodal temperature vector R T q R V CN N dV R T T RV B DB dV A hf NN dA R QN dV A hf TB N dA V surface force vector body force vector displacement vector strain vector frg B L fRg fDre g fDep g fDe g fDp g fUe g fDT g fC th g fDTe g M m1 fK1 g m1 fK2 g rY rX r/ rr stress vector straindisplacement matrix dierential operator matrix R R NT fP g dA V NT ff g dV A nodal stress increment matrix fDe g fDp g elastic stiness matrix plastic stiness matrix nodal displacement vector temperature increment matrix thermal stiness matrix nodal temperature increment matrix temperature shape function R T ep RV BT fDth gB dV B fC gM dV V longitudinal residual stress transverse residual stress circumferential stress radial stresses

inner surface. Ueda et al. [7] investigated the eectiveness of the heat-sink welding to improve the residual stresses of a pipes circumferential joint. Chou and Lin [8] reduced residual stresses by parallel heat welding type 304 stainless steel specimens. For the eect of welding sequence, Weck [9] and Watanabe et al. [10] have studied how welding sequence aect residual stress build-up. Kihara et al. [11,12] investigated how welding sequence aects residual stress and shrinkage in slit-type welds and circular-path welds. Jonassen et al. [1] describes the eects of certain block and other special welding procedures on the magnitude of residual stresses in buttwelded steel plates of 1-in. thickness. When welding a long butt-welded joint, multi-pass butt-welded joint or a path joint, various types of welding sequences are used in order to reduce residual stress and distortion. The selection of a proper welding sequence is an important practical problem. However, accurately predicting the residual stresses of welding sequences is extremely dicult because the thermal and mechanical behaviors in welding include a local high temperature, temperature dependence of material properties, and a moving heat source. Therefore, this investigation performs a thermal elasto-plastic analysis using nite element techniques to analyze the thermomechanical behaviour and evaluate the residual stresses with various types of welding sequence in single-pass, multipass butt-welded plates and circular patch welded plates. Furthermore, this study provides an available welding sequence to improve the fabrication process of welded structures.

2. Analysis model 2.1. Thermomechanical model Welding residual stress distributions are calculated by a nite element method. Fig. 1 presents the analysis procedures. 2.1.1. Thermal model In the thermal analysis, a total of 160 load steps increase from 0.001 to 10 s were required to complete the heating cycle. Only 30 load steps increment were typically required for the weldment to return its initial (room) temperature. The time increments were automatically optimized for each time step by the computer program. The modied NewtonRaphson method was used in each time step for the heat balance iteration. This study simulates weld thermal cycles for SAE 1020 steel are shown in Fig. 2. The convective heat coecients on the surfaces were estimated (using engineering formulae for natural convection) to be 15 W/m2 K. 2.1.2. Mechanical model In the mechanical analysis, the temperature history obtained from the thermal analysis was input as a thermal loading into the structural model. The thermal strains and stresses can be calculated at each time increment. Also, the nal state of residual stresses will be accumulated by the thermal strains and stresses. During each weld pass, thermal stresses are calculated from the temperature distributions determined by the thermal

T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

Boundary Condition
Q

275

Governing Equation
C T + t

{L } { q } =
T

{q} {} = h ( T
T f

TA )

Governing Equation of the Finite

[ C ]T

Element Model T e + [ K ]{ e } = { F } e

Thermal Model Analysis

Temperature Field Te

{ }

Equilibrium Equation
ij , j + f i = 0

Compatibility Equation

Thermal Elasto-Plastic Equation

{ e } = {D ep }[ B ]{U e } {C th }[ M ]{Te }

ij, kl + kl, ij lj , ki
ki,lj = 0

Basic Equation of the Finite Element Model

m +1

{K 1 }{ Ue }

m+ 1

{K 2 }{ T } = { R} e

Mechanical Model Analysis

{Ue}

Displacement Field, Stress Field

{e}

Fig. 1. Flow diagram of the analysis procedure.

1600

1600 .00

1200 .00

800.00
650 700

model. The residual stresses from each temperature increment are added to the nodal point location to determine the updated behavior of the model before the next temperature increment. The material was assumed to follow the von Mises yield criterion and the associated ow rules. Phase transformation eects were not considered in the current analysis due to lack of material information, especially at high temperatures, such as the near-melting state. 2.1.3. Element birth and death The model in this study adopts the technique of element birth and death to simulate the weld ller variation with time in single-pass, multi-pass butt-welded joints and circular patch welds. All elements must be created, including those weld llers to be born in later stages of

Temperature ( C )

400.00
350 200 200 70 18

0.00

18

0.00

0.01

0.10

1.00

10.00

100.00

1000.00

time (sec)

Fig. 2. Simulated weld thermal cycles for SAE 1020 steel.

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T.-L. Teng et al. / Computers and Structures 81 (2003) 273286 Table 1 Schematic of pass sequences along with welding parameters for each pass Pass no. (111) 1 25 6 79 1011 Voltage (V) 25 26 25 26 27 Current (A) 190 215 190 220 250 Speed (mm/s) 3.34 4.70 3.34 4.70 4.70

the analysis. The method proposed herein does not remove elements to achieve the element death eect. Instead, the method deactivates them by multiplying their stiness by a severe reduction factor. Although zeroed out of the load vector, element loads associated with deactivated elements still appear in element-load lists. Similarly, mass, damping, specic heat, and other such eects are set to zero for deactivated elements. The mass and energy of deactivated elements are excluded from the summations of the model. An elements strain is also set to zero as soon as that element is killed. Similarly, when elements are born, they are not actually added to the model, but are simply reactivated. When an element is reactivated, its stiness, mass, element loads, etc. return to their full original values. Thermal strains are computed for newly activated elements according to the current load step temperature. 2.2. Verication To conrm the accuracy of the present method, a specimen was constructed using multi-pass butt-welding, with a length, width and thickness of L 1000 mm, W 400 mm, t 25:4 mm, respectively, as shown in Fig. 3. The welding was done using the submerged arc technique. Pass sequences and welding parameters are shown in Table 1 [13]. The material was assumed to follow the von Mises yield criterion and the associated ow rules. Linear kinematic hardening was assumed.

weld bead

Furthermore, Refs. [13,14] species the mechanical properties and stressstrain curves of base metal, weldmetal, and the heat-aected zone (HAZ) for weldments of ASTM A36 carbon steel. Therefore, these data are used here for the residual stress analysis of the buttwelded joints. The symmetric nite element model has 572 elements and 640 nodes after meshing. The size of the nite element mesh has a great eect on the accuracy of the results and computational cost. To examine the adequacy of element size, eect of mesh renement in the weld area was studied. The new model with rened meshes consists of 696 elements and 771 nodes. Very little dierence in the results between these two dierent mesh models was found. Therefore, the original FEM model without mesh renement in the butt-welded joints can be worked for this verication study. Figs. 4 and 5 portray the distribution of the transverse and longitudinal residual stress on the thick plate. Shim et al. [13] presented experimental results for the same problem. Additionally, the ABAQUS nite element package is applied as a comparison. As the Fig. 4 indicate, the ABAQUS package result showed slightly lower tensile transverse stress near the weld centerline.

1000 mm A

3.00E+8

Present Method Experiment [14]

2.00E+8

ABAQUS [14]

X 400 mm weld bead 4 2 5 3 1

25.4 mm

Residual Stress ( Pa)

25.4 mm

1.00E+8

0.00E+0

6 8 10 7 9 11
-1.00E+8 0.00 0.05 0.10 0.15 0.20

200 mm

X (m)

Fig. 3. Geometry of multi-pass butt-weld.

Fig. 4. Transverse residual stress at the top surface of the plate.

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4.00E+8

277

Present Method Experiment [14] ABAQUS [14]

Residual Stress (Pa)

2.00E+8

0.00E+0

and thickness of the plate are assumed to be 300, 100 and 5 mm, respectively. The plate material is SAE 1020, and the mechanical properties are dependent on the temperature history as illustrated in Fig. 7. As Fig. 7 indicates, mechanical properties of metals change under various conditions when temperature increases, the modulus of elasticity, yield stress and thermal conductivity decrease while the thermal expansion, specic heat and Poisson ratio increase. Furthermore, the width of weld zone was assumed as that of the heat source. Autogeneous weldment was assumed. These means that weld metal, HAZ, and base metal share the same mechanical properties.

-2.00E+8 0.00 0.05 0.10 0.15 0.20

X (m)

Fig. 5. Longitudinal residual stress at the top surface of the plate.

Present method results showed good tendency to the experimental results. As Fig. 5 indicate, both analysis results show tensile stress near the weld centerline. Therefore, the procedure presented here is suitable for analysis of residual stresses and distortions due to welds. 3. Analysis model 3.1. Analysis of the single-pass butt-weld 3.1.1. Specimen and material properties Fig. 6 illustrates two thin-wall plate sections that are jointed by a single-pass butt-weld. The length, the width

3.1.2. Welding conditions The welding parameters chosen for this analysis were as follows: welding method, gas tungsten-arc welding; welding current, I 110 A; welding voltage, V 20 V; and welding speed, v 5 mm/s, respectively. The heat sources are applied along the weld path for practical welds.

3.1.3. A nite element model for the single-pass butt-welds This work develops a two-dimensional symmetrical plane stress model to estimate the residual stresses of the single-pass butt-weld using the nite element method. The model employs two-dimensional four-node plane elements, including the nite element meshes for the butt-welded joint. Fig. 8 demonstrates the nite element meshes for the butt-weld, along with the rened meshes used in the weld area. The symmetric model has 500 elements and 561 nodes after meshing.

Fig. 6. Geometry of single-pass butt-welds.

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6.00

T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

Material Properties Yield Stress Young's Modulus Poisson's Ratio Expansion Conductivity

Material Properties

4.00

Specific He

2.00

0.00 0 400 800

o

1200

1600

2000

Temp ( C )
Symbol -- y ---E --- --- ---k ---c Material Properties Yield Stress Youngs Modulus Poissons Ratio Expansion Conductivity Specific Heat Unit 10 8 Pa 10 11 Pa 10 1 10 5 m m K 10 W K , m2 10 2 J K , Kg

Fig. 7. The mechanical properties of weldments.

3.1.4. Mesh sensitivity study To examine the adequacy of element sizes, the eect of mesh renement in the weld area was studied. The new model with rene meshes consists of 600 elements and 671 nodes. Results from two mesh densities with the same material model and geometry. Figs. 9 and 10 both display the distributions of the longitudinal residual stress rY along the X -direction (at Y 150 mm) and Y -direction with 500 and 600 nite elements mesh model. Very litter dierence in the results between these two dierent mesh models was found. It appears that the main characteristics of the residual stress results from the dierent meshes are almost the same. Therefore, the original FEM model without mesh renement in the weld joint can be worked for this study.

3.2. Analysis of the multi-pass butt-weld 3.2.1. Specimen and material properties Fig. 11 presents two thick-wall plate sections that are joined by a multi-pass butt-weld. The length, width and thickness of the plate are assumed to be 1000, 200 and 12.7 mm, respectively. The mechanical properties are the same as illustrated in Fig. 7. 3.2.2. Welding conditions Four passes were involved in the model. Table 2 lists the welding parameters chosen for this analysis. 3.2.3. A Finite element model for the multi-pass butt-weld This investigation develops a two-dimensional symmetrical plane strain model to calculate the residual

T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

279

1.00E+8

500 elements 600 elements

5.00E+7

0.00E+0

-5.00E+7

-1.00E+8 0.00 0.02 0.04 0. 06 0.08 0.10

Fig. 9. Longitudinal residual stress distribution along the X direction for dierent nite element mesh.

welding current, I 110 A; welding voltage, V 20 V; and welding speed, v 5 mm/s, respectively. 3.3.3. A nite element model for the circular patch welds This study develops a two-dimensional plane stress model to calculate the residual stresses of the circular patch weld using the nite element method. Fig. 13 depicts the nite element meshes for the circular patch welds, along with the rened meshes used in the weld area. The model has 733 elements and 743 nodes after meshing.

Fig. 8. The nite element mesh for the single-pass butt-weld.

stresses of the thick-wall butt-weld using the nite element method. The model employs two-dimensional four-node plane elements, including the nite element meshes for the multi-pass butt-weld. Fig. 11 displays the nite element meshes for the butt-weld, along with the rened meshes used in the weld area. The symmetric model has 192 elements and 231 nodes after meshing. 3.3. Circular patch welds analysis 3.3.1. Specimen and material properties Fig. 12 depicts two thin-wall circular plate sections that are joined by circular patch welds. The radius of the inner plate (R1), outer plate (R2), and thickness (t) of the plate are assumed to be 600, 1500 and 5 mm, respectively. The mechanical properties are the same as displayed in Fig. 7. 3.3.2. Welding conditions The welding parameters chosen for this analysis were as follows: welding method, gas tungsten-arc welding;

4. Results and discussion 4.1. Single-pass butt-weld 4.1.1. Longitudinal residual stresses A stress acting parallel to the direction of the weld bead is termed a longitudinal residual stress, as denoted by the letter rY . Fig. 14 illustrates the distributions of the residual stress rY along the X -direction (at Y 150 mm). High tensile stresses arise in regions near the weld due to a resistance contraction of the material as cooling commences. Compressive stresses occur in regions removed from the weld for self-equilibriating purposes. The maximum stress value is as high as the materials yield stress. 4.1.2. Transverse residual stresses A stress acting vertical to the direction of the weld bead is known as an transverse residual stress, denoted by the letter rX . Fig. 15 represents the distributions of the residual stress rX along the Y -direction. As this gure reveal, the stress distributions are symmetrical at the

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500 elements 600 elements

1.20E+8

1.00E+8
Longitudinal Residual Stress y (Pa)

8.00E+7

6.00E+7

4.00E+7

2.00E+7

0.00E+0

-2.00E+7
-4.00E+7 0.00

0. 05

0.10

0.15

0.20

0.25

0.30

Y-direction (m)
Fig. 10. Longitudinal residual stress distribution along the Y -direction for dierent nite element mesh.

middle of the plate, while the tensile stresses occur at the middle of the plate, and the compressive stresses occur at the end of the weld. 4.1.3. Eect of welding sequences for the single-pass buttweld Reducing the residual stresses in weld structures during an early stage of design and fabrication is of priority concern. For this reason, the eects of welding sequence on the residual stresses are characterized in the following. This research investigates the eect of progressive welding, backstep welding and symmetric welding on residual stresses for a thin-wall butt-weld as revealed in Fig. 16. Figs. 17 and 18 both display the distributions of the longitudinal residual stress rY along the X -direction (at Y 150 mm) and Y -direction with progressive welding, backstep welding and symmetric welding. These gures reveal that the longitudinal residual stresses of symmetric welding are smaller than those of the other welding sequences. Since the symmetric welding reduced restrained force of the weldment

for why the magnitude of the residual stresses are smaller than those of the other welding sequences.

4.2. The multi-pass butt-weld 4.2.1. Longitudinal residual stresses A stress acting parallel to the direction of the weld bead is termed a longitudinal residual stress as denoted by the letter rY . Fig. 19 depicts the distributions of the residual stress rY along the X -direction. The longitudinal residual stress develops from longitudinal expansion and contraction during the welding sequence. A high tensile residual stress arises near the weld bead along the weld line, and then decreases to zero, ultimately becoming compressive as distance from the weld line. The residual stress value (110 MPa) approaches the yield stress of the material. The tensile and compressive residual stress exist at the weld bead and away from the welding line on the plate due to the self-equilibrium of the weldment.

T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

Weld Bead

281

Weld Bead
1000 mm A A

Inner Plate

Z Y

r
X 12.7 mm

Outer plate
400 mm

R1 R2
Weld Bead Weld passes 4 1 2 3

Fig. 12. Geometry of circular patch welds.

Fig. 11. The geometry and nite element mesh for the multipass butt-welds.

Table 2 Welding pass number and parameters for each pass Pass no. Welding parameters Current (A) 1 2 3 4 190 190 215 215 Voltage (V) 25 25 26 26 Speed (mm/s) 3.34 3.34 5.04 5.04 Welding method Gas tungsten-arc welding Fig. 13. Finite element mesh for the circular path welds.

4.2.2. Transverse residual stresses A stress acting vertical to the direction of the weld bead is known as a transverse residual stress as denoted by the letter rX . Fig. 20 presents the transverse residual stress variations at the center of the weld bead (X 0,

Y 500 mm) through the plates thickness. The tensile stress occurred at the upper surface of the plate and was gradually transferred to compressive stress because of the local bending upwards. Furthermore, the stress distributions at both surface areas showed a similar magnitude.

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T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

1.00E+8

300 mm

Longitudinal Residual Stress y (Pa)

5.00E+7

X Y

1 200 mm

0.00E+0

Progressive Welding
-5.00E+7

300 mm
-1.00E+8

X
0.00 0.02 0.04 0.06 0.08 0.10

1 Y

4 200 mm

X-direction (m)

Fig. 14. Longitudinal residual stress distribution along the X direction.

Backstep Welding
1.00E+8

300 mm
5.00E+7
Transverse Residual Stress x (Pa)

X 3
0.00E+0

4 200 mm

Y
-5.00E+7

Symmetric Welding
-1.00E+8

Fig. 16. The dierent welding sequence for thin-wall buttwelds.

-1.50E+8 0.00 0.05 0.10 0.15
Y-direction (m)

0.20

0.25

0.30
1.00E+8

Progressive Welding Symmetric Welding Backstep Welding

Longitudinal Residual Stress Y (Pa)

Fig. 15. Transverse residual stress distribution along the Y direction.

5. 00 E+ 7

4.2.3. Eect of welding sequences for the multi-pass buttweld A butt-welded plate joint of thick plate is considered as a model for analysis under the various welding sequences in Fig. 21. Fig. 22 presents the distributions of the longitudinal residual stress rY with various types of welding sequences. Longitudinal residual stresses between various weld sequences do not appear to signicantly dier. Fig. 23 illustrates the distributions of the transverse residual stress rX with various types of welding sequences. The transverse residual stress rX of case (A) welding procedure is smaller than the other weld sequences. This dierence might be attributed to

0.00E+0

-5.00E+7

-1.00E+8 0.00 0.02 0.04 0.06 0.08 0. 0 1

X- direction (m)

Fig. 17. Longitudinal residual stress distribution along the X direction for dierent weld sequences.

T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

1.00E+7

283

Progressive Welding Backstep Welding Symmetric Welding

7.50E+6

1.20E+8 1.00E+8
Longitudinal Residual Stress y (Pa)

Transverse Residual Stress x (Pa)

5.00E+6

2.50E+6

0.00E+0

8.00E+7 6. 00E+7

-2.50E+6

-5.00E+6

4.00E+7
-7.50E+6

2.00E +7
-1.00E+7

0.00E+0
0.000 0.002 0.004 0.006 0.0080 0.010 .012 0.014 0.016

-2.00E +7

Thickness t (m)

-4.00E+7 0.00 0.05 0.10 0.15 0.20 0.25 0.30

Fig. 20. Transverse residual stress variations at the weld line through the thickness for thick plates.
Y-direction (m)

Fig. 18. Longitudinal residual stress distribution along the Y direction for dierent weld sequences.

1.00E+8

Longitudinal Residual Stress y (Pa)

7.00E+7

Fig. 24 depicts the distribution of circumferential residual stress and reveals that the patch centers residual stress value is 67 MPa, while the inner minimum value is 52 MPa. The vicinity of weld beads HAZ stress value rapidly changes from tensile quickly to compressive stress. This is attributed to equilibrium. Because the outside plates temperature eect is less than the inner one, the material is less compressed and elongated than they. The stress value slowly approaches zero. 4.3.2. Radial residual stress Stresses along the welding normal direction are called radial stresses as denoted by the letter rr . Fig. 25 depicts the distribution of radial residual stress. The residual stresses do not markedly dier from each other because the weld line and patchs radial shrinkage values are almost equivalent. The weldment has a uniform stress eld in the patchs central region and the residual stresses are nearly the same according to Fig. 25. The weldment has a uniform stress eld in the patchs central region and the residual stresses are nearly the same according to Figs. 24 and 25. 4.3.3. Eect of welding sequences for the circular patch welds This work investigates how progressive welding, backstep welding and jump welding aect residual stresses for circular patch welds as illustrated in Fig. 26. Fig. 27 illustrates the distributions of the residual circumferential stress r/ , with various types of welding sequences. The circumferential residual stresses between various weld sequences do not appear to signicantly dier. Fig. 28 depicts the distributions of the radial residual stress rr , with various types of circular patch welding sequences. The radial residual stress rr , of the

4.00E+7

1.00E+7

-2.00E+7

-5.00E+7

-8.00E+7

-1.10E+8 0.00 0.03 0.05 0.08 0.10 0.13 0.15 0.18 0.20

X-direction (m)

Fig. 19. Longitudinal residual stress distribution along the X direction for thick plates.

two reasons: (a) the symmetric welding sequences can reduce the residual shrinkage of the plate or (b) the symmetric welding sequences have pre-heating and postheating eects. 4.3. Circular patch welds 4.3.1. Circumferential residual stress Stresses along the welding tangent direction are called circumferential stress, as denoted by the letter r/ .

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T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

Weld Bead
1.15E+8 9.00E+7
Longitudinal Residual Stress z (Pa)
UP-SURFACE RESIDUAL STRESS z Case : A Case : C Case : B

6.50E+7 4.00E+7 1.50E+7 -1.00E+7 -3.50E+7 -6.00E+7 -8.50E+7

1000 mm A

X 400 mm Weld Bead 4 1 Case(A) 2 3 200 mm

12.7 mm

-1.10E+8 0.00 0.03 0.05 0.08 0.10 0.13 X-direction (m) 0.15 0.18 0.20

12.7 mm

Fig. 22. Longitudinal residual stress distribution along the X direction in various weld sequences for thick-wall butt-welds.

4 2 Case(B) 1 3 200 mm
2.01E+7 1.76E+7
Transverse Residual Stress x (Pa)

TRANSVERSE RESIDUAL STRESS x Case: A

12.7 mm

Case: C Case: B

4 3 Case(C) 1 2 200 mm 12.7 mm

1.51E+7 1.26E+7

1.01E+7 7.64E+6

Fig. 21. The dierent welding sequence for thick-wall buttwelds.

5.14E+6 2.64E+6

backstep welding is smaller than the other welding sequences because the post-weld heat treatment and preheating eect in backstep welding are better than the other welding sequences.

1.40E+5 0.03 0.00 0.05 0.08 0.10 0. 13 0.15 0.18 0.20

X-direction (m)

Fig. 23. Transverse residual stress distribution along the X direction in various weld sequences for thick-wall butt-welds.

5. Conclusion The nite element method is employed herein to evaluate residual stresses in single-pass, multi-pass buttwelds and circular patch welds as well as to discuss how welding sequences aect residual stresses. Based on the results in this study, we conclude the following: An extremely large tensile stress occurs near the weld bead and a compressive stress appears away from the

weld bead in longitudinal residual stresses along the X direction for single-pass and multi-pass butt-welds. The residual stresses are almost uniformly distributed along the welding direction in longitudinal residual stresses along the Y -direction for single-pass butt-welds, except those near the two ends of the weld. A tensile residual stress is produced at the center region of the plates, and then suddenly becomes compressive near the two ends of the weld in transverse re-

T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

1.20E+8 1.00E+8
Circumferential Residual Stress (Pa)

285

progressive welding

8.00E+7 6.00E+7

4.00E+7 2.00E+7

0.00E+0 -2.00E+7

-4.00E+7 0.00 0.15 0.30 0.45 0.60 0.75 0.90 Radius r(m) 1.05 1.20 1.35 1.50

backstep welding

Fig. 24. Circumferential residual stress distribution for circular patch welds.
2
7.70E+7 7.20E +7 6.70E+7

Radial Residual Stress r (Pa)

6.20E+7 5.70E+7

3
5.20E+7 4.70E+7 4.20E+7 3.70E+7 3.20E +7 2.70E+7 0.00 0.15 0.30 0.45 0.60 0.75 0.90 1.05 1.20 1.35 1.50

jump welding

3
Radius r (m)

Fig. 25. Radial residual stress distribution for circular patch welds.

sidual stresses along the Y -direction for single-pass buttwelds. Tensile stress occurs at the upper surface and is gradually transferred to compressive stress at the bottom surface in transverse residual stresses through the plates thickness for multi-pass butt-welds. In circumferential residual stress for circular patch welds, the weldment has a uniform tensile stress eld in the patchs central region, and then decreases to compressive, nally becoming zero as distance from the weld bead. In radial residual stress for circular patch welds, the weldment has a uniform tensile stress eld in the patchs

Fig. 26. The various welding sequences for circular patch welds.

central region, and the residual stresses do not markedly dier away from the weld bead. Dierent welded geometrical congurations or welded joints have various available welding sequences that

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T.-L. Teng et al. / Computers and Structures 81 (2003) 273286

Circumferential Residual Stress Progressive Welding Backstep Welding Jump Welding

1.20E+8 1.00E+8
Circumferential Residual Stress (Pa)

8.00E+7 6.00E+7

sequence for single-pass welds. In multi-pass welds, case (A) weld procedure is an available welding sequence. Backstep welding is an available welding sequence for circular patch welds. More free space should be available for expansion and shrinkage in the welding structure during the welding procedure to prevent the rigid restraint in the weld bead, and, consequently, to decrease the residual stress.

References
4.00E+7 2.00E+7

0.00E+0 -2.00E+7

-4.00E+7 0.00 0.15 0.30 0.45 0.60 0.75 0.90 Radius r (m) 1.05 1.20 1.35 1.50

Fig. 27. Circumferential residual stress distribution in various weld sequences for circular patch welds.

Radial Residual Stress r Progressive Welding Backstep Welding Jump Welding

7.70E+7 7.20E+7 6.70E+7

Radial Residual Stress r (Pa)

6.20E+7 5.70E+7 5.20E+7 4.70E+7 4.20E+7 3.70E+7 3.20E+7 2.70E+7 0.00 0.20 0.40 0.60 0.80 Radius r(m) 1. 00 1.20 1.40

Fig. 28. Radial residual stress distribution in various weld sequences for circular patch welds.

depend on the restraints that happen during the welding procedure. Symmetric welding is an available welding

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