Modeling and validation of residual stress distribution in an HSLA-100 disk (original) (raw)
Related papers
Metals, 2018
Dissimilar welds close to the fusion boundary exhibit a variety of solidification microstructures that strongly impact their service behavior. Investigations were therefore undertaken to clarify the origins of the morphological and microstructural evolutions encountered in a 18MND5/309L dissimilar joint produced by submerged arc welding, using a combination of microstructural characterizations, thermodynamic computations, and solidification modelling. An unexpected evolution was observed in the solidification mode, from primary austenite towards primary ferrite with increasing growth rate. Solidification of austenite at the fusion boundary was assigned to its epitaxial growth on the metastable austenitic structure of the base metal resulting from an incipient melting mechanism. The evolution of the solidification mode toward primary ferrite was explained based on computations of the solute built up between austenite cells followed using the so-called "interface response function model". Analyzing macro-and microstructural characteristic lengths with the published solidification model and data enabled evaluation of local values of the solidification rate, thermal gradient, and cooling rate close to the fusion boundary, thus providing useful data for numerical modelling of the submerged arc-welding process.
Modelling and Simulation in Materials Science and Engineering, 2004
The microstructure exerts a strong influence on the mechanical properties and on the integrity of welded joints. Prediction of the formation of the microstructure during welding and of other solidification processes may be an important and supporting factor for technology optimization. Nowadays, increasing computing power allows direct simulations of the dendritic and cell morphology of columnar grains in the molten zone for specific temperature conditions. Modelling is carried out, on the one hand, with the finite difference-cellular automata and, on the other hand, with the phase field method. Determination of the solidification conditions during fusion welding (temperature gradient, local solidification rate, weld pool shape) is carried out with a numerical macroscopic finite element modelling calculation of the weld pool fluid flow and of the temperature distribution, as presented in this paper. As with the use of accurate physical models, the simulations are carried out with a spatial resolution of the microstructure, and many assumptions and restrictions from traditional, analytical or phenomenological models may be eliminated. The possibilities of using numerical algorithms for generation and visualization of microstructure formation during solidification are demonstrated. The spectrum of applications extends from welding and casting to processes with rapid solidification. In particular, computer simulations of the solidification conditions and the formation of a dendritic morphology during the directional solidification in gas-tungsten-arc welding are described. Moreover, the simulation results are compared with the experimental findings.
Materials Science and Technology
The sensitivity of residual stress distributions in bainitic-martensitic steel welds to the transformation strains that arise when austenite decomposes on cooling has been assessed by examining the predictions of three models for a simple bead-on-plate configuration. These cover the following scenarios: case I, no phase transformations; case II, transformations with volume change effects only; case III, transformations with volume change effects and associated Greenwood-Johnson transformation plasticity. Austenite decomposition was predicted by implementing Kirkaldy's reaction rate equations as a subroutine in the finite element code Sysweld, eliminating the need for a continuous cooling transformation diagram. Predicted residual stresses were then compared and rationalised alongside measurements obtained by neutron diffraction and the contour method. It was found that serious errors in predicting the location and magnitude of the peak stresses occurred if transformations were not included, while cases II and III gave similar results generally in agreement with the stress maps. Indeed, the trends in the experimental results were intermediate between cases II and III. Differences between the models and the potential for further improvements are discussed.
1992
During welding, structures are subjected to localized heating and cooling cycles, as described in Part I.[1] A mathematical model is proposed to determine the metallurgical changes that occur in austenitic stainless steel due to the welding thermal cycle. The proposed kinetic model computes the austenite grain growth as a function of time and temperature. It is based on a Zener pinning grain growth model. The results obtained indicate that the model is in good agreement with the experimental data reported in the literature. Furthermore, it was observed that rewriting the kinetic constant in the grain growth equation as a function of the peak temperature led to improved results for the majority of the cases examined.
Complex thermal stresses generated in welded structures are undesirable but inevitable in fusion welding. The presence of residual stresses can be detrimental to the integrity of a welded joint. In this research, redistribution of residual stress magnitude and profile was studied and compared in two multi-pass welded structural alloys (API X100 and 304L stainless steel) after cold rolling and laser processing. The residual stress field was studied by neutron diffraction using the SALSA strain scanner at their reactor neutron source at ILL, Grenoble. In addition to a complex distribution of residual stress state, multi-pass welds also forms dendritic grain structure, which are repeatedly heated, resulting in segregation of alloying elements. Dendritic grain structure is weaker and segregation of alloying elements may result in formation of corrosion microcells as well as reduction in overall corrosion prevention due to depletion of alloying elements in certain areas. The modification of as-welded residual stress state was done by cold rolling which was followed by laser processing to create a recrystallized microstructure to minimise segregation. The main objective of this study is to understand the suitability of this novel manufacturing technique to create a stress free weldment with recrystallised grain structure. Hardness evolution in the welded structures was scanned following welding, post weld cold rolling and cold rolling followed by laser processing. Hardness distribution in both the structural alloys showed a significant evidence of plastic deformation near the cap pass of the weld metal. Residual stress redistribution was observed up to 4 mm from the capping pass for ferritic steel, while in austenitic steel weld, post weld cold rolling was effective in modifying the residual stress redistribution throughout the entire thickness. Laser processing in both cases reinstated the as-welded residual stress distribution and resulted in softening of the strained area.
Metallurgical and Materials Transactions A, 1997
The microstructure of three 12 pct cr steel weld metals with different nickel and nitrogen contents was studied in as-welded condition and after postweld heat treatment with and without intercooling. Tensile strength and impact toughness of the weld metals were investigated in different postweld heat treatment conditions. In weld metals heat treated without intercooling, austenite decomposed by a eutectoid reaction that resulted in M 23 C 6 aggregates around retained ␦-ferrite. Two morphologies of M 2 N and MN precipitates were found in a low-dislocation ␣-ferrite. It was concluded that these phases were also transformed from austenite. In weld metals heat treated with intercooling, M 23 C 6 precipitates were smaller and more homogeneously distributed. Different MN precipitates were found in the tempered martensite. The fracture mode of the weld metals at room temperature was mainly transgranular cleavage with some fibrous fracture. Intercooling treatment improved Charpy impact toughness of the 12 pct Cr steel weld metals substantially. It was found that the important microstructural factors affecting the impact toughness of the weld metals which were heat treated without intercooling were the sizes of the ␣-ferrite grains, nonmetallic inclusions, and M 23 C 6 aggregates. For the weld metals heat treated with intercooling, the factors which affect the toughness of the weld metals were the sizes of martensite packets and nonmetallic inclusions.
Study of the Stress State of a Dissimilar Metal Weld Due to Manufacturing and Operational Conditions
Periodica Polytechnica Mechanical Engineering, 2022
Welding is accompanied by the presence of weld residual stresses, which in case of dissimilar metal welds even with post weld heat treatment cannot be removed completely therefore they should be considered when assessing possible welding defects. The measurement of residual stress in metal weld is a very complex procedure and also in the investigated case could not be carried out as it is the part of a working plant. However, by modelling these processes, the residual stresses and deformation of the components caused by this manufacturing method can be determined. It is important to calculate these values as accurately as possible to determine the maximum load capacity of the structure. The structure under examination was the dissimilar metal weld of a VVER-440 steam generator. 2D simulations were performed, where temperature and phase-dependent material properties were implemented. Different loading scenarios were considered in the numerical analysis. The results can be useful to d...
2014
Dissimilar welds between low-alloy steel and stainless steel are numerous within the French nuclear power plants where they enable connecting the main components to the primary circuit pipes. The internal cladding (in stainless steel) of the pressure vessel (in bainitic steel) made by submerged arc welding is another case of dissimilar weld whose goal is the protection against corrosion. This PhD work aims at understanding the complex microstructures which form at the interface between both steels during welding together with their evolution during the post-weld heat-treatment at 610°C and their consequences on the mechanical behavior of the welded assembly. Starting from the base metal, one meets successively a thin layer of martensite, a fully austenitic zone and the two-phase δ/γ microstructure of the stainless steel. Microscopy techniques (SEM, EDS, EBSD) combined with thermo-kinetics calculations (Scheil-Gulliver model, dendrite tip undercooling) have allowed explaining the gra...