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net ISSN (ONLINE): 2250-0758, ISSN (PRINT): 2394-6962

Volume-5, Issue-2, April-2015

International Journal of Engineering and Management Research
Page Number: 390-397

Finite Element Modeling of TIG Welding for 316L Stainless Steel

Plate using Sysweld
V. V. Narayanareddy1 , D. Srinivasa Rao2 , M. N. V. Krishnaveni 3, M. Amareswarireddy4
1,2,3,4
Assistant Professor, Department of Mechanical Engineering, Anits Engineering College, Visakhapatnam,
Andhra Pradesh, INDIA

ABSTRACT element model for welding residual stress analysis in

In this present work numerical simulation of
thermal phenomena during welding of 316L stainless steel
plate. Different bead-on-plate weld trials conducted on 3
mm thick plate with 120-160 Amp heat input at a different
welding velocity from 120 - 180 mm/min. On the basis of
experimental results the influence of welding current and
speed on the shape and size of fusion zone in bead-on-plate
is compared with simulation. A three dimensional Double
ellipsoidal heat source model and temperature dependent
thermo physical properties of 316L steel are used for
thermo-mechanical analysis of TIG welding in SYSWELD
software. Based on bead-on-plate experiment and
prediction correlation an optimized parameter for 3 mm
thick used for final weld plate. During welding of final weld
plate thermal cycles are measured using thermocouple
further compared with finite element analysis results.
Amount of heat power density distribution is predicted
using SYSWELD is compared with analytical density in
MATLAB. An isotherm curve distribution in molten zone
pool for different weld velocity for a heat input variation is
predicted.
Keywords---- 316L stainless steel, thermal analysis,
Fusion zone, SYSWELD, heat power density, TIG
welding.
I. INTRODUCTION
The process of welding is an integral part of
manufacturing of nuclear components and has a direct
influence on the integrity of the components and their
thermal and mechanical behaviour during service. In
fusion welding process due to localized heating and
cooling, residual stresses and distortion are inducing in
the welded component [1-2]. Many investigators have
developed numerical models for studying the effect of
welding process on the welding characteristics 316L
stainless steel is a regular choice in power plant and
super critical nuclear application. Many researchers
published work on thermo mechanical analysis of
stainless steel welding like, D. Deng proposed finite
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ABAQUS [4,5]. A.H. Yagi measured residual stress and
thermal data for thick cylinder using multi pass welding
by element birth technique in ABAQUS .From literature
it is observed that number of researchers have been
working on analytical and computational welding
analysis of GTA welding process for thick pipe and plate
austenitic steel but for thin plate of austenitic stainless
steel material still need some serious attention. During
welding the interaction [6,8,9] of the heat source and the
parent metal leads to rapid heating and melting with
vigorous circulation of molten metal in the weld pool.
This thermal cycle plays an important role in
determining weld geometry, HAZ dimensions, weld
metal and, residual stress and deformation. Undesirable
affects from thermal cycles of welding may occur in the
zone of solidified metal (weld metal) or in the heat
affected base metal (Heat affected zone). Localized
melting or amount of fusion penetration in to a joint
being welded is controlled mainly by heat input, but
other subtle features like weld speed and arc length also
can exert an effect. The peak temperature reached by the
weld area can determined the extent of grain growth in
the heat affected zone, as well as that amount of
softening that may take place in the heat affected zone of
work-hardened base metal[7,11]. During GTA Welding
weld plate interacts with arc for a short period of time
only and it comes under very high heating and cooling
cycles, during this short time plate is subjected complex
thermal cycles. This condition makes welding process in
to more complicated for getting desired solution using
analytical modelling. Therefore numerical technique is a
preferable option for studying complex process with
small increment time interval. The problem of distortion,
residual stresses, and reduced strength of a structure in
and around a welded joint are a major concern of the
welding industry for decades. These problems primarily
result directly from the thermal cycle caused by localized
intense heat input in arc welding process [13,14.15].
Hence for the development of effective simulation
strategy for weld analysis, the accurate prediction of
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thermal history is of key importance. Finite element
analysis gives capability for modelling of temperature
distribution nearer to welding and heat affected zone in
terms of temperature and molten zone.
II. NUMERICAL SIMULATION
The weld plate model is considered as a solid body.
A moving heat source model is made in the meshing file
to present the heat generated by the torch in the TIG
welding process. The Goldak’s double-ellipsoid heat
source model is adopted to calculate volumetric heat flux
distributions as heat input around the welding pool. The
heat source distribution as shown in Fig 4 combines two
different ellipses, i.e. one in the front quadrant of the
heat source and the other in the rear quadrant. The power
densities of the double-ellipsoid heat source, q f (x, y, z)
and q r (x, y, z), describing heat flux distributions inside
the front and rear quadrant of the heat source.[3,10]
Gaussian distribution of power density (W/m3)
in an ellipsoids amount of heat applied per unit volume.
The heat density Q(x, y, z) at an arbitrary point within
the front half ellipsoid and the rear half ellipsoid is
described by the following equation
6 3ffQ −3 x 2 / a f 2 −3 y 2 / b2 −3[ z + v (τ −t )]2 / c 2
Q ( x, y , z , t ) = e e
a f bcπ π
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6 3 f r Q −3 x2 / ar 2 −3 y2 / b2 −3[ z +v (τ −t )]2 / c12
Q ( x, y , z , t ) = e e e
a f bcπ π
Where a f, a r, b, c are the ellipsoidal heat source
parameters, a f is front length of molten pool, a r is rear
length of molten pool, c is depth of penetration in all
cases and b is half width as shown in fig 1 . Q is the arc
heat input, η is welding efficiency, V and I are arc voltage
and current, f f and f r proportional coefficient at front and
rear ellipsoid of the heat source respectively, such that f f +
f r =2, and V is the welding speed. For all weld analysis
double-ellipsoid parameters are measured at 75%
welding efficiency (η).
III. EXPERIMENTAL WORK
Fig 2 shows the final weld plate experimental
setup with backup plate same set up is used for all bead-
on-plates and final weld plate welding. Temperature
history nearer to weld line is recorded using K type
thermo couple with sampling length 2 cycle placed at 5,
10, 12, 15 and 18 mm away from weld line as shown in
Fig 2. During welding thermal cycles history is recorded
in data logger. Experimental heat input paramters used
for bead-onplate and obtained weld length and width are
given in table1. Bold paramters are used for final weld
plate. Experimental work on Automatic GTA Welding
machine for 3 mm thick 316L stainless steel bead-on-
plate is carried out at a different heat input for a different
weld speed. After welding, weld sample is prepared
using cutting machine and roughly polished with flexible
abrasive paper to remove surface impurities and
irregularities, further cleaned with acetone.
e
Fig 2 Weld Plate Experimental Setup
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S.no Current Voltage Welding Weld Width Arc

(amps) (volts) Speed length(mm) b(mm) length(mm)
(mm/min)

1 160 12.6 120 15.49 8.9 1.5

2 140 12.2 120 15.1 8.8 1.5

3 130 12 120 14.6 8.74 1.5

4 120 11.6 120 14.5 8.6 1.5

5 160 14.8 140 7.5 6.3 1.5

6 140 11.6 140 7 6.6 1.5

7 130 11.4 140 8.7 6.3 1.5

8 120 11.3 140 8 5.7 1.5

9 160 11.2 140 6.8 5.3 1.5

10 140 12.8 160 7.9 6 1.5

11 130 12.6 160 8.54 6.74 1.5

12 160 12.2 160 8 6 1.5

13 140 11.9 160 7.6 6.2 1.5

14 130 11.8 180 7.8 5.8 1.5

15 120 11.6 180 7.5 5.7 1.5

16 130 11.5 180 7.6 5.2 1.5

17 120 11 180 7.3 5.2 1.5

Table 1 Heat source fitting parameters for different heat input.

Fig 3 shows bead-on-plate nugget profile for a (Goldak) are weld length, depth of penetration and weld
different heat input at weld speed of 140 mm/min, Heat width for each bead-on-plate measured using optical
source fitting parameters for double ellipsoidal model microscope as shown in Fig 3 (c).

(a) 160 Amps (b) 130 Amps

(C) 140Amp (d 120Amp

Fig 3. Bead On plate for different current at 140 mm/min weld velocity

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IV. HEAT SOURCE FITTING
The first part of the sequentially coupled
elastic-plastic thermo-mechanical analysis is discussed
here in the present study and the effects of various heat
source and welding process parameters on transient
temperature distributions, boundary and shape of FZ and
HAZ are presented in detail. Weld profile obtained by
FEA is compared with result by optical microscope for
each bead-on-plate with minimum error as shown in Fig
4 .The shape of molten zone profile is almost same with
bead shape profile observed in experiment. It is evident
that there is good agreement between these two sets of
results with minimum error.

Fig 4 Experiment Weld profile with Simulated Result

Fig 5 (a-d) shows the cross section of weld speed 140 mm/ min at 1.5 mm arc length, there was a
profile comparison for experimental and finite element good agreement between experimental and Fea model.
analysis result at 120-160 Amp current range for welding

(a) 160 Amp (b) 140 Amp

(c) 130 Amp (d) 120 Amp

Fig 5 Comparison of Experimental Weld profile with Simulated Results at different current

V. HEAT POWER DENSITY
Fig 6 shows the heat power density comparison
of weld nugget profile as obtained using finite element
analysis, MATLAB (analytical) and experimental
results. Heat power density is the amount of heat
concentrated on welded plate for a particular heat input.
For checking accuracy of heat power density by finite
element analysis using Goldak’s heat distribution model
as shown in Fig 6 (a) is compared with analytical results
in Fig 6 (b) for 160Amp current at 140 mm/min weld
speed. The heat power density is calculated by self
developed MATLAB code based on simple heat input
power calculation using double ellipsoidal model. Heat
power density is estimated to be 45w/mm3 by MATLAB
and 47w/mm3 by finite element analysis.

Goldak’s Heat source distribution model

Fig 6. Heat Power density at 160 Amp

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VI. RESULT AND DISCUSSION
6.1Thermal Analysis of Final weld plate
Double ellipsoidal model parameters measured
by experiment for 160 Amp current at 140 mm/min weld
speed are a f = 2.8 mm, a r = 3.8 mm , b = 5.3 mm, c = 3
mm. Using these parameters, thermal analysis of final
weld plate is presented in Fig 13 at various stages of
welding. It is evident from the figure that the temperature
around the torch reaches 1510oC suggesting melted
material in the fusion zone (FZ). Next to fusion zone, the
presence of higher temperatures indicates the presence of
heat affect zone. A small area ahead of the heat source
also shows comparatively higher temperature because of
the front parameter of heat source model. The heat input
from the heat source to the weldments gradually
transferred to the rest of the base plate in all directions
due to conduction, convection and radiation phenomenon.
The peak temperature obtained during welding simulation
is 1640oC . Fig 7 (a-b) shows the higher temperature
gradient is located at the welding line. The boundary of
molten pool is defined by isotherm representing 1640oC.

(a) Initial Stage of weld at 18 sec (b) Middle Stage of weld at 41 sec

Fig 7. Finite elment Thermal analysis of welding

Fig 8 Temperature distribution in transverse direction

Fig 9 Position of thermocouple (a) 18 mm

(b) 15 mm (c) 12 mm

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(d) 10 mm (e) 5 mm

Fig 10 Temperature evolution at 5 characteristics location from weld line.

Thermal history for Final weld plate is recorded
using five thermo couple at a marked characteristic
location during GTA welding process. Position of five
thermocouples on welding plate is shown in fig 9.
Thermal history during welding process is recorded up to
room temperature using five thermocouple placed at 5
mm, 10 mm, 12 mm, 15 mm and 18 mm from weld line
on the top of weld plate. Fig 10 (a-e) shows the
comparison of measured thermal cycles using
thermocouple with finite element thermal analysis
results. The peak temperature obtained by thermocouple
at 5 mm distance from weld line is1052oC and
thermocouple reading is 1039oC temperature. The peak
temperature for 10 mm distance from weld line is by
thermocouple is 714oC and FEA is 704oC, only 10 oC
difference is observed. Similarly for 12, 15 and 18 mm
distance peak temperature of simulated and experimental
have good agreement.
6.2 Cooling rate Comparison
Finite element analysis of cooling rate
for Final weld plate at 160 Amp current for 140 mm/min
weld speed is shown in Fig 11. The maximum heating
and cooling rate is taken in the quasi-steady state
condition. From the temperature rate the heating and
cooling rate observed are 222°C/s, and -110.8°C/s
respectively. It has no much change during quasi-steady
state and it can be considered as maximum in the
welding process. The heating and cooling rate obtained
by experimental work is compared through FE analysis
result for 5 to 18 mm distance from weld line.

Fig 11 Cooling rate at 160 Amp

6.3Isotherms for different weld speed
Fig 12.(a –c) shows the isothermal
lines of the weldment surface temperature for 120 Amp
at 120 mm/min, 140 mm/min, 160 mm/min and 180
mm/min welding speeds. Increase in weld speed is
reducing the peak temperature obtained during welding.
Weld pool size, weld width, weld depth and the heat-
affected zone are also decreased for constant welding
parameters. Welding pool becomes large at welding
speed 120 mm/min, the bottom layer remelts in welding
upper layer because of lower welding speed and local
overheat. The welding pool is small and shallow with
incomplete penetration for 180 mm/min weld speed, so
140 mm/min is chosen for final weld plate. It can be
concluded that a few changes of welding speed have
great impact on welding pool formation; temperature
gradient and distribution in weldment.

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(a) 120 mm/min
Fig 12. Isotherm Lines at 120 Amp Current input
VII. CONCLUSIONS
In this study, a systematic procedure followed
to perform the thermal analysis during the autogenous
TIG welding of 316L stainless steels. A Gaussian
distributed moving heat source model based on Goldak’s
heat source model is implemented in SYSWELD and
experimentally validated for the 3D finite element
simulations of arc welding process. Based on the
research work it is conclude that the variation in total
heat energy input to the metal i.e. variation of welding
process parameters primarily welding current and weld
speed significantly affects both the boundaries
(magnitude) and shape (heat distribution) of FZ and
HAZ along with affecting the peak temperatures in both
the zones. Other important investigation here is that the
peak temperature which is depended upon the total heat
input is also varied. In Study the effects of welding
process parameters on the temperature profile, fusion
and heat affected zones. Different heat inputs are used by
varying the welding process parameters. In the numerical
model the parameters are calibrated based on the bead-
on-plate experiments. Calibrated weld fusion zone
profile by optical microscope has been compared with
heat source fitting tool with a good agreement.
Numerically observed fusion zone isotherm profile is
validated by thermocouple result which has good
agreement. Measured thermal cycles has been compared
with Finite element thermal analysis result at 5 mm , 10
mm, 15 mm and 18 mm distance form weld line. It is
noticed that the temperature follow a non-linear trend
which is caused by the non-linear material properties
used in the process. The heating and cooling rates has
been validate at various instance in the quasi-steady state
condition. Changes in heating and cooling rate have been
compared for both with and without preheat welding.
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