An iterative technique for the reconstruction of residual stress fields in a butt-welded plate from experimental measurement, and comparison with welding process simulation

Jazeel Rahman Chukkan, Guiyi Wu, Michael E. Fitzpatrick, Steve Jones, Joe Kelleher

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

Residual stress is a factor which potentially affects the integrity of welded components. We have developed a methodology of assessment to establish the state of residual stress in a butt-welded plate by using a limited set of experimental measurements obtained using neutron diffraction. The unique longitudinal and transverse residual stress components, as a result of the welding process, are measured across the weld in three depths through the thickness. The measured residual stresses are then used to estimate a stress distribution for each stress component. The estimated stress distribution is then mapped to a finite element model of the weld plate, before adopting an iterative solution to reconstruct the residual stress fields. In addition, a traditional welding simulation is performed using the same weld plate details to predict and compare the residual stress distributions. It is shown that accurate residual stress field reconstruction is possible in and around the area of measurement using the limited measurement data from the neutron diffraction technique. In the estimated stress profiles, an upper-bound distribution is implemented in the weld and Heat Affected Zone (HAZ). This increases the efficiency and reduces the complexity of modelling. In the meantime, conservatism in the estimated stress is secured.

Original languageEnglish
Pages (from-to)421-428
Number of pages8
JournalInternational Journal of Mechanical Sciences
Volume160
Early online date2 Jul 2019
DOIs
Publication statusPublished - 1 Sep 2019

Fingerprint

welding
stress distribution
residual stress
Residual stresses
Welding
Welds
simulation
Stress concentration
Neutron diffraction
neutron diffraction
iterative solution
heat affected zone
Heat affected zone
integrity
methodology
estimates
profiles

Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in International Journal of Mechanical Sciences. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in International Journal of Mechanical Sciences, 160, (2019) DOI: 10.1016/j.ijmecsci.2019.07.001

© 2019, Elsevier. Licensed under the Creative Commons AttributionNonCommercial-NoDerivatives 4.0 International
http://creativecommons.org/licenses/by-nc-nd/4.0/

Keywords

  • Finite element method
  • Neutron diffraction
  • Residual stress
  • Residual stress mapping
  • Residual stress relaxation
  • Welding process modelling

ASJC Scopus subject areas

  • Civil and Structural Engineering
  • Materials Science(all)
  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering

Cite this

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abstract = "Residual stress is a factor which potentially affects the integrity of welded components. We have developed a methodology of assessment to establish the state of residual stress in a butt-welded plate by using a limited set of experimental measurements obtained using neutron diffraction. The unique longitudinal and transverse residual stress components, as a result of the welding process, are measured across the weld in three depths through the thickness. The measured residual stresses are then used to estimate a stress distribution for each stress component. The estimated stress distribution is then mapped to a finite element model of the weld plate, before adopting an iterative solution to reconstruct the residual stress fields. In addition, a traditional welding simulation is performed using the same weld plate details to predict and compare the residual stress distributions. It is shown that accurate residual stress field reconstruction is possible in and around the area of measurement using the limited measurement data from the neutron diffraction technique. In the estimated stress profiles, an upper-bound distribution is implemented in the weld and Heat Affected Zone (HAZ). This increases the efficiency and reduces the complexity of modelling. In the meantime, conservatism in the estimated stress is secured.",
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AU - Kelleher, Joe

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N2 - Residual stress is a factor which potentially affects the integrity of welded components. We have developed a methodology of assessment to establish the state of residual stress in a butt-welded plate by using a limited set of experimental measurements obtained using neutron diffraction. The unique longitudinal and transverse residual stress components, as a result of the welding process, are measured across the weld in three depths through the thickness. The measured residual stresses are then used to estimate a stress distribution for each stress component. The estimated stress distribution is then mapped to a finite element model of the weld plate, before adopting an iterative solution to reconstruct the residual stress fields. In addition, a traditional welding simulation is performed using the same weld plate details to predict and compare the residual stress distributions. It is shown that accurate residual stress field reconstruction is possible in and around the area of measurement using the limited measurement data from the neutron diffraction technique. In the estimated stress profiles, an upper-bound distribution is implemented in the weld and Heat Affected Zone (HAZ). This increases the efficiency and reduces the complexity of modelling. In the meantime, conservatism in the estimated stress is secured.

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