A finite element model to predict the evolution of stress and distortion for a bead on plate tungsten inert gas (TIG) weld in aluminium alloy 2024 plate is described. The thermal model was calibrated against thermocouple measurements, and the mechanical model was validated against direct measurements of residual strain made using synchrotron X-ray diffraction. Particular attention has been paid to the clamping arrangement, the transfer of heat between the plate and the copper backing plate, and the selection of appropriate thermal history dependent mechanical properties. The validated model has been used to determine the optimal arrangement for ‘low stress no distortion’ welding using laser heating applied to both sides of the joint line ahead of the TIG torch. In this manner it is predicted that the peak longitudinal tensile stresses in the weld region can be reduced to 15% of their normal values.
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