Abstract
This study examined the through-thickness residual stress in multi-pass welding joint via a coupled experimental/numerical approach. For a numerical approach, an integrated welding simulation model between arc plasma process and thermo-mechanical behavior during welding was developed. Then, the iterative substructure method was adopted for a fast simulation to solve welding thermo-mechanical problems. Using the developed modeling and simulation techniques, the through-thickness residual stress in multi-pass welding joint was estimated from welding process and heat input conditions, without preliminarily observed weld bead morphology and measured temperature profiles obtained by welding experiments. Meanwhile, the experimental measurements were conducted using stress relief method and deep hole drilling techniques. Through the comparisons of weld bead morphology, temperature profiles and through-thickness residual stress, the usefulness of developed modeling and simulation technique was discussed. As the results, we concluded that the developed modeling and simulation techniques have great potential to be efficient residual stress analysis with a high degree of accuracy.
