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Residual stresses in friction stir welded Al sheets

http://link.springer.com/article/10.1007/s003390201830
In this study, the influence of a coolant applied during welding of Al sheets on the residual stress state
of the FSW joint was investigated. Liquid CO2 coolant was applied near the weld seam for rapid
cooling of the weld zone. The residual stresses across the weld were measured by neutron diffraction.
Three sheets were produced, one without cooling, and two with cooling, where two different distances
of the coolant nozzles from the FSW tool were chosen. The results show that, by applying a coolant,
the magnitude of the tensile stress in the center of the weld can be reduced significantly.
Friction stir weld
Rapid cooling
Neutron diffraction

Numerical simulation of postweld heat treatment of 15MnNiCrMoV steel impeller


https://www.researchgate.net/publication/282681659_Numerical_simulation_of_postw
eld_heat_treatment_of_15MnNiCrMoV_steel_impeller?
ev=srch_pub&_sg=6vrv8SEy3hVTRIevAUYUINvbJekAe2hBH4aSOwnBY0rIrslnKya9v4AxOz8UDHn.WGdFN_4S8mhouDEo5O_W1G1JSbAFFO5T0mPZj76Q66u9oSix1
QdZ92LiCUW5VxC4.V1togXBtkX1MX502C1muWkToQ2gToUKrF16eiwx93fWXGklSSQxu
CPmxzIzTHlRF

The results show that after welding, the equivalent stress of impeller is relative large and the
maximum equivalent stress reaches 996 MPa. Meanwhile, the residual stress is mainly concentrated in
the weld seam of air inlet. After heat treated at 650, 700 and 750 for 5 hours respectively,
residual stresses of the overall impeller and weld seam reduce obviously
FEM
Heat treatment

Effect of the mutual position between weld seam and reinforcement on the residual stress distribution in
Friction Stir Welding of AA6082 skin and stringer structures
https://www.researchgate.net/publication/295082770_Effect_of_the_mutual_position_between_weld_seam
_and_reinforcement_on_the_residual_stress_distribution_in_Friction_Stir_Welding_of_AA6082_skin_and
_stringer_structures?
ev=srch_pub&_sg=hXpNKyHk5Onl0fV9aTxMQHc7I7stgWDhfBX65eSu7XDAjr80iiWJzhojtmF52i8.l1y8VgRh7IHwf-9yM5DT-74u2rDLs9NdIIF542M2PjMEqtwYqTZnFgCv92l1KaC.nGoWoOSbU7h5bdOPhwGYCXBskyLPCXfDtaAqMEw9yW4Qw2UY5WWZDcT0rT_jcp2
In the paper, a numerical and experimental study was carried out to highlight the effect of the
distance d between the weld seam and the reinforcement on the residual stress distribution in Friction
Stir Welded AA6082-T6 structures. An L-shaped profile was welded to a sheet metal with varying tool
rotation and distance d from the weld seam. The Cut Compliance method was used to determine the
resulting longitudinal residual stress. A dedicated FE model for FSW was set up, validated and utilized
to predict the longitudinal residual stress in the assembled part. The analysis allowed the identification
of a few design guidelines in order to reduce the detrimental effects of the residual stresses.
FEM
Friction stir weld
Distance from weld seam
Cut compliance method

Measurement of internal residual stress of thick-walled pipe using local material removal method
https://www.researchgate.net/publication/286117992_Measurement_of_internal_residual_stress_of_thick-

walled_pipe_using_local_material_removal_method?
ev=srch_pub&_sg=IKluA74ekFafy_UADuoXAD9cjmvzElG3phH7J4GldhFEMsbiE3e3w3UhFpVnjejT.j2r
Xj89FXjOImHkEzHHYXI0TuULyiELvppdMnidN01xGjM1OROoYCxxZyhzXyoAE.eiAOHf5jrfujj2tM7
p5W7lfL74nRbrtxwHDrX6mzFVeY3shBlhFiItPt-1OfcJN2
The local material removal blind hole method was used to measure the internal residual stress of a
thick-walled pipe after post weld heat treatment (PWHT), then the distributions of axial and
circumferential residual stresses in the pipe after PWHT were obtained. The results indicate that the
magnitude and distribution of the internal residual stress in the thick-walled pipe after PWHT can be
obtained effectively by this method; the axial stress tends to be compressive in the weld region and
tensile on the inner and outer surfaces far from the weld seam; the peak value of the tensile stress
appears in the heat-affected zone near the outer surface; the circumferential stress is tensile in the
weld region and its peak value appears near the inner surface of the pipe; while the stress in the base
metal adjacent to the weld seam is compressive. The overall level of the residual stress in the thickwalled pipe after PWHT is relatively small, and the circumferential and axial stresses are reduced
below 100 MPa.
Blind hole
Axial stress
Circumferential stress
Compressive
Tensile
Heat affected zone

Numerical analysis of welding residual stress of U-rib stiffened plate


https://www.researchgate.net/publication/286991547_Numerical_analysis_of_welding_residual_stress_of_
U-rib_stiffened_plate?ev=srch_pub&_sg=NyoqLOAie5r1ijKt9tK5FDJlAL5cHepPnjRysXOEygjoEO849L3kmX9sTfR4-l8.HHR-B6H1Q2FGA70bWsj-FLDfMvK45PtymyRncU0oLAYX1Q7Jp3ygb4bKhjJxfhp.P38iKkj2ABsW3J565hNIOHeodnUgMB5MamlPNwVAsh6a6lg
P9OQq2zTGka_us9wj
In order to take into account the change of stress and deformation during the whole process of
welding and the thermal field distribution of a U-rib stiffened plate, a thermal elastic-plastic FEM model
was adopted and element birth and death was used to simulate the weld seam fill-in and heat input.
And the residual stress distribution was investigated by numerical simulations and experiments. The
comparison of numerical analyses and experimental results of distribution and magnitude of residual
stress showed that residual stress near the weld seam is close to material yielding stress, the average
value of the residual stress far from weld seam on the mother board was around 0.2 time of material
yielding stress. The residual stress distribution tendency derived from numerical simulation was close
to the experiment result, which proved the validity of the numerical simulation.
FEM
Element birth and death
Yield stress

High pressure rolling of low carbon steel weld seams: Part 2 - Roller geometry and residual stress
https://www.researchgate.net/publication/247774219_High_pressure_rolling_of_low_carbon_steel_weld_s
eams_Part_2_-_Roller_geometry_and_residual_stress?
ev=srch_pub&_sg=BUP438iIlKBNJmcnQvLgM1c6YvGG0HR_GjdWVORwafLen0vABv_6FGF59LJmiE
C0.eV_RlPGg2KTSX9fr7S99Z_VZdxxKGfU2pxTNmGcteWhBqBVOk_fUDZp_ylWbg4E.zl1o2Fck3ndbVeG6C
LtS38vkW5xDOWg8Tp6FP9H_8aFSGQh3Np5XE_TOF1EB0tMm
localised high pressure rolling of the weld seam is a proposed method for eliminating them. In this
study, neutron diffraction has been used to map the residual stresses within low carbon steel weld
seams treated with high pressure rolling. The effect on the residual stress distribution of using
different roller types was determined, along with the influence of these different rollers on final weld
seam geometry. Rolling was found to completely change the residual stress state in the weld, creating
large compressive longitudinal residual stresses. It was effective for this purpose regardless of whether
it was applied directly to the weld seam or to regions either side of it. The fatigue life of welded

specimens was shown to be reduced by rolling; however, it is suggested that this is due to geometric
and metallurgical effects.
High pressure rolling
Neutron diffraction
Stress distribution
compressive
fatigue

Residual stress modification by post-weld treatment and its beneficial effect on fatigue strength of welded
structures
http://www.sciencedirect.com/science/article/pii/S0142112303001919
A compressive stress induced by post-weld treatment is beneficial by eliminating the tensile residual
stresses and generating compressive residual stresses, which improves fatigue strength of welded
structures. A study is underway to characterize the magnitude and subsurface distribution of residual
stresses produced by post-weld treatments, particularly by Ultrasonic Impact Treatment (UIT), and to
establish the post-weld treatment effect on fatigue resistance. Two post-weld treatments, UIT and shot
peening, are involved in the present study. Internal stresses were investigated on three base metal
samples treated by UIT and shot peening and on one welded sample treated by UIT through neutron
diffraction and X-ray diffraction techniques. This paper presents the experimental conditions and the
results of these stress measurements. It is revealed that the peak compressive residual stress induced
by both treatments exceeded the yield stress of the base material near the sample surface. The depth
of compressive stress layer in base metal was 1.51.7 mm for UIT and ~0.8 mm for shot peening. The
induced compressive residual stresses benefit to increase the threshold value of stress intensity factor
range, Kth, for fatigue crack initiation and early propagation. The effect of residual stresses
modification on fatigue strength is discussed based on fracture mechanics model and verified by
fatigue test results of large-scale welded beams.
Tensile
compressive
Fatigue
Post processing
Ultrasonic impact treatment
peening
neutron diffraction
X-Ray diffraction
stress intensity factor

FEM prediction of welding residual stress and distortion in carbon steel considering phase transformation
effects
http://www.sciencedirect.com/science/article/pii/S0261306908001556
The objective of this study is to investigate the effects of solid-state phase transformation on welding
residual stress and distortion in low carbon and medium carbon steels. In this study, based on ABAQUS
code, a sequentially coupled thermal, metallurgical, mechanical 3-D finite element model is
developed. In the numerical simulations, different continuous cooling transformation diagrams are
used to predict the fractions of martensite for the fusion zone, the coarse-grained HAZ and the finegrained HAZ, respectively. Effects of volume change due to austenitemartensite transformation on
the final residual stress and the welding distortion are examined. The simulation results revealed that
the final residual stress and the welding distortion in low carbon steel do not seem to be influenced by
the solid-state phase transformation. However, for the medium carbon steel, the final residual stresses
and the welding distortion seem to be significantly affected by the martensitic transformation.
FEM
Metallurgy

Continuous cooling transformation diagram


Martensite
Heat affected zone

Dependence of the microstructure, residual stresses and texture of AA 6013 friction stir welds on the
welding proces
http://www.hanser-elibrary.com/doi/abs/10.3139/146.030908
to study the influence of the friction stir welding process on the material and in order to determine the
influence of different welding parameters. The results of the investigations reveal the influence of the
process parameters (welding speed, tool diameter and rotational speed) on the weld properties such
as the microstructure, the precipitation state, the hardness, the texture and the residual stresses. The
formation of the residual stresses and their distribution is explained based on an existing, simple
thermal model for the friction stir welding and on a classical model for the formation of the residual
stresses in conventional fusion welding.
Friction stir weld
Process
Speed
tool diameter
rotational speed

Microstructure and Residual Stress Formation in Induction-Assisted Laser Welding of the Steel S690QL
http://onlinelibrary.wiley.com/doi/10.2374/SRI08SP106/abstract
In this work, the effect of induction-assisted laser welding on the microstructure and residual stresses
in S690QL butt joints was investigated. The results reveal that conventional laser welding causes
strong martensite formation in the weld seam and the heat-affected zone. This leads to prohibitive
hardness values. Induction heat-treatments result in an efficient reduction of hardness in the fusion
zone. However, the efficiency decreases with increasing sheet thicknesses. The residual stress
distributions after laser welding with and without induction heating are typical of fusion welding.
Although an effective reduction of hardness is achieved by induction-assisted laser welding, the
residual stresses remain significantly high.
Martensite
Heat affected zone
Heat treatment

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