Computational prediction of out-of-plane welding distortion and experimental investigation - Awarded Central Electricity Generating Board Prize

D. Camilleri, T. Comlekci, T.G.F. Gray

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56 Citations (Scopus)

Abstract

The main aim of the work was to investigate a simplified finite element simulation of the out-of-plane distortion caused by fusion butt welding. The thermal transient part of the simulation made use of a finite element analysis of the two-dimensional cross-section of the weld joint and the thermoelastic-plastic treatment was based on analytical algorithms describing transverse and longitudinal deformations, leading to predictions of transverse angular deformation and longitudinal contraction force. These results were then applied to a non-linear elastic finite element model to provide predictions of the final angular and overall deformations of the butt-welded plates. The validity of the simulation was investigated via full-scale tests on 4m x 1.4m x 5 mm steel plates, butt welded using a flux-cored Ar-CO2 metal-inert gas process. Thermography and thermocouple arrays were used to validate the thermal transient computations and out-of-plane deformations were measured using displacement transducers for transient deformations and a laser scanning system to measure the profiles of the whole plates before and after welding. The results of six full-scale tests are given and comparison with the simulations shows that the procedure provides good prediction of the angular and overall out-of-plane deformations. Prediction accuracy requires account to be taken of initial shape, gravity loading, and support conditions.
Original languageEnglish
Pages (from-to)161-176
Number of pages15
JournalJournal of Strain Analysis for Engineering Design
Volume40
Issue number2
DOIs
Publication statusPublished - Jan 2005

Fingerprint

Welding
Electricity
Experimental Investigation
Prediction
Transverse
Butt welding
Simulation
Laser Scanning
Thermoelastic
Finite Element Simulation
Inert gases
Thermocouples
Transducer
Finite Element Model
Plastics
Transducers
Contraction
Steel
Gravity
Fusion

Keywords

  • welding distortion
  • welding simulation
  • butt welds
  • angular deformation
  • mechanical engineering
  • engineering design
  • strain analysis

Cite this

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title = "Computational prediction of out-of-plane welding distortion and experimental investigation - Awarded Central Electricity Generating Board Prize",
abstract = "The main aim of the work was to investigate a simplified finite element simulation of the out-of-plane distortion caused by fusion butt welding. The thermal transient part of the simulation made use of a finite element analysis of the two-dimensional cross-section of the weld joint and the thermoelastic-plastic treatment was based on analytical algorithms describing transverse and longitudinal deformations, leading to predictions of transverse angular deformation and longitudinal contraction force. These results were then applied to a non-linear elastic finite element model to provide predictions of the final angular and overall deformations of the butt-welded plates. The validity of the simulation was investigated via full-scale tests on 4m x 1.4m x 5 mm steel plates, butt welded using a flux-cored Ar-CO2 metal-inert gas process. Thermography and thermocouple arrays were used to validate the thermal transient computations and out-of-plane deformations were measured using displacement transducers for transient deformations and a laser scanning system to measure the profiles of the whole plates before and after welding. The results of six full-scale tests are given and comparison with the simulations shows that the procedure provides good prediction of the angular and overall out-of-plane deformations. Prediction accuracy requires account to be taken of initial shape, gravity loading, and support conditions.",
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author = "D. Camilleri and T. Comlekci and T.G.F. Gray",
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