Available online at wwwsciencedirect.com sornnce Goinacr- ‘Computational Materials Science 37 (2006) 269-277 COMPUTATIONAL MATERIALS. SCIENCE wow elsvir com/locateeommatei Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements Dean Deng *, Hidekazu Murakawa Joining ond Welding Research Insitute, Osaka University, H-1, Miogaoka, Iara, Osaka 8670047, Japan Received 22 March 2005; revived in revised form 7 June 2005; accepted 12 July 2005 Abstract A computational procedure is presented for analyzing temperature fields and residual stress states in multi-pass welds in SUS304 stainless steel pipe. Based on the ABAQUS software, uncoupled thermal-mechanical three-dimensional (3-D) and two-dimensional (2-D) finite element models are developed. The finite element models are employed to evaluate the transient temperature and the residual stress fields during welding. Firstly, a 3-D model is developed to simulate the temperature fields and welding residual stresses. Secondly ‘based on the characteristics of the temperature fields and the welding residual stress fields, a 2-D axisymmetric model is also developed. ‘The simulated result shows that the 2-D axisymmetric mode! can be efectively used to simulate the thermal eycles and the welding resid ual stresses for SUS304 stainless steel pipe. Using the 2-D model, a large amount of computational time ean be saved. In this study, experiments are also carried out to verily the effectiveness of the proposed numerical models. The results of both 3-D model and 2-D. ‘model are in very good with the experimental measurements, (© 2005 Published by Elsevier B.V. PACS: 44.25 07.10.L; 7215.6: 81.20.V “Keywords: Finite element method: Numerical simulation: Temperature fel Welding resid stress; Mullspass welds 1. Introduction Welding is a reliable and efficient metal joining process. ‘The welding process is used in almost all industries. The circumferential butt-weld is a common type of joint in stainless steel piping systems in power plant. Owing to the relatively large wall thickness in such piping systems, the butt-weld is often constructed of several weld passes Due to the intense concentration of heat in the welding, the regions near the weld line undergo sever thermal cycles. The thermal cycles cause non-uniform heating and cooling in the material, thus generating inhomogeneous plastic deformation and residual stresses in the weldment. The Corresponding author, Tel: +81 48451 SR5S; fax: 8148 451 5655, Eomail address: dengisstom.co jp (D. Deng) 10827-02565 - se Front matter © 2008 Published by Ekeviee BLY, doi10.1016.commatsc.2008.07.007 presence of residual stresses can be detrimental to the performance of the welded product. Tensile residual stres- ses are generally detrimental, increasing the susceptibility of a weld to fatigue damage, stress corrosion cracking ‘and fracture [1]. When assessing the risk for growth of de- fects such as surface flaws in piping systems the welding residual stress may give a large contribution to the total stress field than stress caused by design loads [2]. More- over, in order to prevent inter-granular stress corrosion cracking in the root area of welds in stainless steel, it is nec- essary to satisfy certain requirements concerning process condition, material properties and welding residual stress. Therefore, a good estimation of the welding residual stress field is then needed, The distribution of welding residual stress depends on several main factors such as structural dimensions, material270 D. Dong, H. Murakava ! Computational Materials Science 37 (2006) 263-277 properties, restraint conditions, heat input, number of weld pass and welding sequence. Hence, for multi-pass welding the welding residual stresses may be very complex, and it is very difficult to predict the distribution of welding resid- ual stress due to the multi-pass welding operation. Over the last decade or so, a number of finite element ‘models [1-3,5-10] have been proposed to predict tempera- ture fields and residual stresses in multi-pass butt-welded steel pipe, Brickstad and Josefson [2] employed two-dimen- sional (2-D) axisymmetric models to numerically simulate a series of multi-pass circumferential butt-welds of stainless steel pipe up to 40mm thick in a non-linear thermo- ‘mechanical finite element analysis. Mochizuki et al. (6) used inherent strain analysis and thermal elastic plastic analysis to predict residual stress in carbon steel pipe, and they verified their aumerical models using neutron diffraction ‘measurement. Wen et al. (7] also used a two-dimensional axisymmetric finite clement (FE) model to simulate three- ‘pass pipe girth welding with wall-thickness of 19 mm, Tsai ct al. [8] employed a three-dimensional shell clement and ‘moving welding arc to simulate welding residual stress in AISI 304 stainless pipe. Li et al. (9] developed a full ‘three-dimensional FE model to simulate a multi-pass, nar- row gap girth Welding process, and their research suggested that more experimental residual stress measurements on pipe weldments are needed to verify the numerical mode. Recently, Jiang and co-workers [10] used a three-dimen- sional FE model to predict temperature distributions in a ‘multi-pass welded piping branch junction, However, weld- ing residual stresses was not conducted in their research, ‘The past studies suggest that it is necessary to continue to carry out experiments to verify the numerical models for multi-pass butt-welded steel pipe. In addition, itis also nec- essary {0 compare the simulated results of 3-D model with, those of 2-D axisymmetric model. 3-D model can capture temperature fields and residual stress distribution in details during multi-pass welding process, however, a very long time is required because the mechanical phenomena in welding are strong non-linear transient problems, It is ‘meaningful that a large amount of time can be saved if the 3-D model can be replaced by a 2-D axisymmetric model In the present study, based on the ABAQUS software, a three-dimensional (3-D)model is developed to simulate the temperature fields and the welding residual stress fields in SUS30¢ stainless steel pipe at first. Based on the character istics of the temperature fields and the residual stress ficlds in the SUS304 stainless steel pipe, a 2-D axisymmetric model is also created to calculate the temperature ficlds and the welding residual stresses. Moreover, experiments are also carried out to verify the effectiveness of the pro- posed computational procedures. 2, Experimental procedure ‘The material used in this work is SUS304 pipe with out- cr diameter of 114.3 mm, thickness of 6 mm, and length of 800mm. The welding pipe and the shape of groove are schematically shown in Fig. 1. The filler metal is Y308L. Gas tungsten arc (GTA) welding process is used in the experiments. Welding condition is shown in Table 1, and welding direction is shown in Fig. 2. The pipe is welded by two pass welding method. The inter-pass temperature is slightly higher than room temperature (25 °C), which is approximately 50°C In the experiments, the thermal cycles at several loca- tions on inside and outer surfaces are measured using the thermo-couples as shown in Fig. 2. After completion of welding, the strain gauges with 1 mm length are used to measure the welding residual stress. The locations of the strain gauges are shown in Fig. 3 ‘After measuring the released strains in the circumferen- tial direction and the axial direction, the hoop stresses 0 and the axial stresses , can be calculated according to the following equations Table 1 Welding condition Pass Current (A) Voltage (V)_ Speed Net heat input (emai) (kfm) rr) 95 0 07 2 160 9s 0 on Fig. 1. Dimensions of welded pipe and shape of groove.D. Deng, H. Marakawa | Computational Materials Science 37 (2006) 260-277 sanior es 20° 90" 180 Fig. 4, Locations of strain guuges, Ele =¥5)/(-¥) £(6 + va)/-¥) a) ®) where ¢, is the released strain in the circumferential direc- tion, ¢, is the released strain in the axial direction; E is Young's modulus of elasticity, and v is Poisson's ratio, 3. 2D FE modeling ‘The temperature fields and the evolution of the residual stresses arc investigated by means of finite clement meth- od. In order to accurately capture the temperature fields and the residual stresses in the welded pipe, a 3-D finite clement model is developed. The thermo-mechanical behavior of the weldment during welding is simulated using uncoupled formulation, because the dimensional changes in welding are negligible and mechanical work The heat conduction problem is solved independently from the stress problem to obtain temperature history, However, the formulation considers the contributions of the transient temperature field to the stress analysis through thermal expansion, as well as temperature-depen- dent thermo-physical and mechanical properties. The solu- tion procedure consists of two steps. First, the temperature distribution and its history in the welding model is computed by the heat conduction analysis, Then, the temp- crature history is employed as a thermal load in the subse- quent mechanical elastic plastic calculation of the residual stress field, In this study, all analyses are performed using ABAQUS. code, The base metal and weld metal are defined as differ- cent materials, The thermal physical properties and mechan- ical properties of the base metal are shown in Table 2. For the weld metal, only the yield stress is higher than that of done is insignificant compared to the thermal energy from the base metal, the other properties are almost the same the welding arc, as the base metal, Table 2 Thermal physical properties and mechanical propertis of SUSSOS Temperature Specie Conductivity Density Yield “Thermal expansion Young's Poissos co heat G/e*C) —Gimam°Cs)_(g/inm®)__ revs (MPA) —_coeflcint CC") modulis (GPa) ratio ry 046 001s 0790 265.00, Tite 19850 0.204 100.00 0496. ois one 218.00, 17he-s 19300 029 200.00 sia 0161 078 186.00 Late 15.00 301 300.00 0595 0179 om = ym.00 1860-5 7600 o310 400.00 040 ois ons 15500 19ie-s 16700 Osis 00.99 ost 0208 076 = 149.00 1960-5 159.00 a6 300.00 0.604 0.0289 0186 91.00 22 3100 0333 12000 0676 0.0822 on 25.000 2oTe-5 0.00 039 10000 692 oon one 21.000 aut s 20.000 ou 1500.0 0.700 120 on. 1000 2160-5 10.000 038