Abstract
Abstract
Arc fusion welding predominates in the welding industry as a reliable joining method and has been the subject of investigations by researchers for decades. To ensure in-service structural integrity, optimization of weld-induced imperfections such as welding deformations and residual stresses is critically desirable in circumferentially welded thin-walled cylinders owing to their wide applications in aerospace and aeronautical structures, pressure vessels, and nuclear engineering fields. In this research, computational methodologies for sequentially coupled non-linear transient thermomechanical analysis of the complex arc welding of thin-walled cylinders of stainless steel (AISI 304) are presented. Detailed three-dimensional finite element (FE) simulations with a single V butt-weld joint configuration of 150 mm outer diameter and 3 mm wall thickness cylinders are carried out to investigate the effects of varying structural boundary conditions (mechanical constraints) on weld-induced distortions and residual stress fields. Basic FE models are validated with carefully recorded and properly instrumented experimental data for temperature distribution, deformations, and residual stresses. Predicted and measured welding distortions and residual stresses are compared and discussed in detail. The results reveal that axial deformations are strongly dependent on the degree of restraints. Low-restraint structures exhibit high axial shrinkage, and vice versa. Diametral/radial shrinkage for different clamping conditions show no significant variation. Further, residual stresses show a weak dependence on the degree of restraints. Although the stress levels slightly vary in magnitude, a similar trend is observed for all the structural clamping conditions studied.