Challenges in the Calculation of Residual Stresses in Thick-walled Components

Challenges in the Calculation of Residual Stresses in Thick-walled Components

J. Klassen, T. Nitschke-Pagel, K. Dilger

Abstract. Numerical simulations of welding induced residual stresses and distortion is still a challenging task, especially with regard to thick-walled structures. These structures are mostly welded with high numbers of layers. Usually adjacent welds influence each other. Therefore, simple 2D calculations become unsuitable, thus, leading to the necessity of 3D transient calculations. In turn 3D multi-layer welding simulations require large finite element models. To account for steep temperature gradients in the weld and the heat affected zone each layer has to be modeled using rather fine elements. Thus, numerical models become very large regarding the degrees of freedom. Significant simplifications are common practice, although it is known that these might cause inaccurate or even wrong results. The current paper presents 3D transient finite element simulations of welding residual stresses and distortions in multi-layer welds of 29mm thick-walled components of a construction steel grade S355N. Furthermore, several modelling simplification approaches were applied. During welding temperature profiles were recorded to validate numerical models. After each layer residual stress measurements were carried out by means of X-ray diffraction (XRD). Furthermore, some weld fill levels were investigated by neutron diffraction (ND). This allowed the comparison of real through-thickness residual stress distributions with numerical simulations.

Keywords
Residual Stresses, Numerical Welding Simulation, Multi-Layer Welds

Published online 12/22/2016, 6 pages
Copyright © 2016 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: J. Klassen, T. Nitschke-Pagel, K. Dilger, ‘Challenges in the Calculation of Residual Stresses in Thick-walled Components’, Materials Research Proceedings, Vol. 2, pp 299-304, 2017

DOI: http://dx.doi.org/10.21741/9781945291173-51

The article was published as article 51 of the book Residual Stresses 2016

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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