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Part 1: Recent Progress In Analysis Of Residual Welding Stresses: Modeling of Weld Residual Stresses and Distortions: Computational Procedures and Applications

Modeling of Weld Residual Stresses and Distortion: Computational Procedures and Applications highlights recent developments in advanced weld modeling procedures. First, the multi-faceted process physics and mechanics associated with welding are briefly outlined: 1) the effects of fluid flow and heat transport in weld pool, high-temperature material behavior, residual stresses and distortions; 2) an engineering perspective for today's industrial applications for residual stress and distortion predictions; 3) a unified weld constitutive model for finite element simulation of welding processes; 4) residual stress effects on structural integrity; 5) outline of future challenges in modeling weld residual stresses and distortions.

Part 2: Recent Progress In Analysis Of Residual Welding Stresses: A Fast Thermal Solution Procedure for Analyzing 3D Multi-Pass Welded Structures

Fast Thermal Solution Procedure for Analyzing 3D Multi-Pass Welded Structures describes a new transient, explicit, and closed-form comprehensive thermal solution procedure (CTSP) for simulating the heat flow process associated with welding of complex welded structures. The solution techniques can be used to analyze multi-pass and curved welds in complex structures with convective heat loss along boundaries. The fast solution procedures are particularly suited for residual stress and distortion prediction in complex structures. Otherwise, finite element based heat flow solutions can be extremely time-consuming and require a different mesh design from the mechanical analysis due to its different convergence requirements. The fast solution procedures have been validated with experimental data and used for many industrial applications. A set of selected validations and application examples are summarized in this paper to highlight its unique advantages in analyzing realistic structures, particularly for residual stress and distortion predictions.

Part 3: Recent Progress In Analysis Of Residual Welding Stresses: Finite Element and Experimental Study of Residual Stresses in a Multi-Pass Repair Weld

Finite Element and Experimental Study of Residual Stresses in a Multi-Pass Repair Weld summarizes the study of residual stresses induced in a multi-pass repair weld in a thick section test plate, a butt-welded base plate restrained by transverse strong back stiffeners. The repair excavation is centered upon the original weld and is wide enough to encompass the weld and a minimum of 10 mm beyond each fusion boundary. A V-shaped flat-bottomed repair weld preparation is used with a depth of 35mm. The excavation of the repair weld is formed by machining and hand grinding. The excavation is then welded using a four-layer temper bead technique with 135 repair passes to fill the cavity.

A global-to-local computational model is used to predict the residual stresses in the repair weld. The global 3-D model is used to capture the overall structural deformation during repair. With the input of restraints from the global model, a local 2-D cross section model is used to capture residual stress details at the mid-section of the repair weld. Experimental measurements on the residual stress distributions are also carried out using center hole drilling, X-ray diffraction, and deep hole techniques. Both surface and through-thickness residual stress distributions show good agreement between the predictions and measurements, particularly in the repair area.

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Published: 2000 Number of Pages: 38 File Size: 1 file , 1.7 MB