Original Article

Proc IMechE Part E:

J Process Mechanical Engineering
Analysis of thermal stresses and 0(0) 1–8
! IMechE 2020
its effect in the multipass welding Article reuse guidelines:
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process of SS316L DOI: 10.1177/0954408920965062
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Harinadh Vemanaboina1 , Suresh Akella2,

AC Uma Maheshwer Rao2, Edison Gundabattini3 and
Ramesh Kumar Buddu4

Abstract
In this work, simulation has been carried out for multipass Gas tungsten Arc Welding of SS316L and their effects were
studied for thermal, and residual stresses and compared with experimental results. The sequentially coupled thermo-
mechanical, transient thermal and static structural analysis was modelled using ANSYS with relevant Ansys Parametric
Design Language coding. Infrared thermography camera was used to obtain the real time temperatures during the
welding. The effect of temperatures and the induced residual stresses of the weldment is measured with X-Ray dif-
fraction technique. Tensile residual stresses have been identified at fusion zone and compressive stresses at heat affected
zone. Pass wise temperature measurements were taken from analysis and experiment the agreement with 7.24%.
The agreement of measured and analysed residual stress had an agreement with 16.66%.

Keywords
Multipass welding, GTAW process, infrared thermography, residual stresses, finite element analysis
Date received: 17 April 2020; accepted: 16 September 2020

Introduction
Welding process is one of the significant metals join-
ing techniques used in the industrial sector. Varieties
of welding technique are available for metal joining in
industrial application, in which Gas Tungsten Arc
Welding (GTAW) is one of the growing popular
welding techniques extensively used in manufactur-
ing, maintenance and repair industry.1,2 Joining of
stainless-steel materials has an advantage in the
reduction of weight and cost of the component.
Stainless steels materials widely used in automobile,
nuclear industries, power and chemical plants.
Welding of thick plates with the single pass is leading
to defects like weldability, hot cracking which further
leads to structural failures. These complications can
be overcome by adopting with multi-pass welding
process3–6 with an improved structural and mechani-
cal properties of weldments. Ramesh et al.7,8 had
investigated the effect of heat input on the structural
and mechanical behaviour of 60 mm SS316L plate
using multipass. The Electron beam welding process
is employed for joining the plates, where the EBW
process had advantages compared to arc welding pro-
cess due to its narrow fusion and HAZ of the plate.
The weldments are free from defects for both GTAW
and EBW processes which is varied by X-ray radiog-
raphy and ultrasonic scan test. The superior mechan-
ical results are seen for EBW joints, because of its
localised heat input.
Many authors have used the finite element analysis
(FEA) as an alternative to reduce the production cost
at the design phase. 3 D weld structure was modelled
using the different boundary conditions with simula-
tion packages. The non-linear behaviour of tempera-
ture and residual stresses in the weldment can be
analysed accurately. User subroutine was developed
with ABAQUS/ANSYS code packages, which are
1
Sri Venkateswara College of Engineering and Technology
(Autonomous), Chittoor, Andhra Pradesh, India
2
Sreyas Institute of Engineering and Technology, Hyderabad, Telangana,
India
3
School of Mechanical Engineering, Vellore Institute of Technology,
Vellore, Tamil Nadu, India
4
Institute of Plasma Research, Gandhi Nagar, Gujarat, India
Corresponding author:
Harinadh Vemanaboina, Sri Venkateswara College of Engineering and
Technology (Autonomous), Chittoor, Andhra Pradesh, India.
Email: harinadh.vh@gmail.com
2 Proc IMechE Part E: J Process Mechanical Engineering 0(0)
growing in welding process simulation with coupled or
decoupled thermo-mechanical analysis with volumetric
heat flux for thermal analysis.9,10 The temperature-
dependent thermo-physical properties are used. From
the simulation process, it was observed that martensite
transformation causes the residual stresses in the weld-
ments. The axial stresses in the weldment are
experiencing the tension at fusion zone and heat-
affected zone undergo compressive compared to the
fusion zone, and the weldment goes to compressive
stress and ends with zero. The temperatures, residual
stress, and distortions were understood from the exper-
iment using the GTAW process. Accurate measured
stress values were obtained using XRD on the top sur-
face in the transverse direction. Similar locations were
used to measure distortion values using the vertical
height gauge.11–13
The plastic-strain-range finite element models were
developed for butt joints for Gas Metal Arc Welding
(GMAW) process. The residual stresses distribution
had reported with the effect of both isotropic harden-
ing and non-linear kinematic hardening in the weld-
ments.14 Experimentation process is carried out with
GMAW by varying the heat input, voltage and weld-
ing current with three levels of each parameter.
The residual stresses measurement is carried out
with the hole drilling method. Authors observed
that in all the three specimens the maximum residual
stress was observed at the top surface and gradually
decreases moving into the depth of the weld specimen.
The FEA and experimental results were compared,
and a close agreement was obtained. In another
work by Lostado et al.15,16 had developed the finite
element models to understand the thermal behaviour
and its effects on angular distortion and bead geom-
etry of the butt weldments with the GMAW process.
Authors had used the genetic algorithms (GA) with
multi-objective functions for the analysis. The effect
of heat input shows the increasing trend of angular
distortion and bead geometry of the weldments. The
FEA models and experimental results show a prom-
ising correlation.
3D modelled17–19 the welding simulation for stain-
less steel plate materials using the FEA. Accurate
predictions of the distributions of temperature, dis-
tortion and stresses in the butt joint. The stress was
varied in the weldment is due to the effect of the heat
input and its thermal boundary conditions. The peak
temperature profile was observed at fusion zone and
residual stresses experiencing compressive stresses at
the edge of the plates. Thermo-elastic-plastic simula-
tions laser butt welding of AISI 316 L by using the
conical, conical with double ellipsoidal and cylindri-
cal shell heat sources by Rahman et al.20 Authors
developed model using FEA to understand the ther-
mal cycles, residual stresses and distortion in the
welds. Measurements of validation were first estab-
lished by using calibrated thermocouple sensors for
the thermal, ultrasonic technique for stresses and
vertical height gauge for distortions. The conical
heat source shows promising results when compared
with other heat source models. Suresh et al.21–23 have
established the model for the laser and electron beam
welding process to understand the temperature distri-
bution and residual stresses. The Kaplan model,
Gaussian and frustum heat flux models with circular
and line surface loads applying for welding simulation
process. Authors concluded with map thermal, distor-
tion and stress parameter distributions in the weld-
ments for nuclear applications.
During the welding process, the weld bead and
associated areas experience plastic deformation, due
to heating and cooling cycles and thus obtain the
residual stresses. The residual stress in the weldment
is influenced by heat generated and effect inter lattice
spacing where finally changes in microstructure and
the thermo-mechanical stresses obtained. The amount
of thermal effect in the weldment can be predicted by
thermo-mechanical analysis under given boundary
conditions using FEA packages.12,16,18 To the best
of the authors’ knowledge, it is observed that no
work was reported in the current literature about
the experiments addressing towards in situ analysis
of thermal behaviour during GTAW for SS316L
material which lacks confirmation on simulations
for estimation of temperature profiles, and residual
stresses. The current proposed works mainly concen-
trate on simulation and analysis of multipass welding
of SS 316L with GTAW process conditions. The 3D
analysis includes thermal and Residual stresses distribu-
tion of the welded parts. The thermo-mechanical anal-
ysis is carried out with APDL coding in the ANSYS
package. Measurement of temperatures during the
welding process using Infrared Thermography. The
residual stresses are measured using the X-Ray
Diffraction after the weldment cools to ambient tem-
perature for validation.
Finite element analysis
Temperature-dependent24 thermal and structural
properties of the base material were used for this anal-
ysis. The FEA is conducted using the APDL in
ANSYS for modelling and simulation. The transient
thermal analysis is carried out using the SOLID70
element and SOLID 45 is used for structural analysis.
The two types of mesh options are used for the sim-
ulation models. The finer mesh is applied at fusion
zone with a mesh size of 1.5 mm and coarse mesh is
applied rest of the plate with a mesh size of 3 mm as
shown in Figure 1. In the simulation process, they are
two types of loads, the first one is the internal loads
like the connectivity of the meshed parts, displace-
ment of the results is taken care of by the ANSYS
package. The secondary loads are external loads
called initial loads, boundary conditions, external
loads like thermal and mechanical loads has to
defined by the user. The volumetric heat flux is
Vemanaboina et al.
Figure 1. Volumetric meshing of the model used for
simulation.
Figure 2. Dissimilar welding of Multipass GTAW process.
chosen as a heat source for the simulation for all the
passes. The welding cycle time was about 40 sec due to
variation in the transient thermal for all the three
passes. The cooling cycle was maintained for about
1000 sec in between the intermediate weld passes to
maintain necessary interpass temperatures.
The proposed analysis is carried out in 3-stages. In
the first stage, the model was built in 3-Dimension,
materials properties assigned, and the meshing is car-
ried out. In stage-2 the loads and boundary condi-
tions are defined, according to weld pass. The
temperatures were taken at various zones of the weld-
ment. In stage-3 static structural analysis is couple
with thermal analysis was carried out. The residual
stresses are estimated for each pass of the weldment.
The volumetric heat flux25,26 of each weld pass is
determined using the following equation:
Q ¼ gUI=V
where g is the arc welding efficiency, U is the voltage,
I is welding current and V is the volume of weld pass.
The volume of the bead is added for each as shown in
Figure 2. The arc efficiency of 65% is assumed.27 The
heat conduction equation for welding simulation is
given by (equation (2)):
     
@ @T @ @T @ @T @T
k þ k þ k þ Q ¼ qCp
@x @x @y @y @z @z @t
3
where q is the density, Cp is the specific heat under
constant pressure, k is the parent material conductiv-
ity. The coefficient of heat transfer rate was calculated
for the weldment (equation (3)). Heat loss by convec-
tion was applied at the top and side faces of the weld-
ment while heat loss by both convection and radiation
(equation (4)) was taken into account over the surface
of the third weld bead obtained during the last weld-
ing run. In equations (4) and (5), T0 is the ambient
temperature,e is the emissivity of the parent materi-
al,ris the Stefan-Boltzmann constant, and h, is con-
vective heat coefficient.
H ¼ 24:1  104 eT1:61 (3)
qc ¼ hðT  T0 Þ (4)
qr ¼ erðT4  T0 4 Þ (5)
Boundary conditions for the simulation
1. For pass-1 initial temperatures was ambient
temperature.
2. Convention was applied at the root opening of the
plates for pass-1 and pass-2.
3. In pass-3 both convection and radiation were
specified only on the top surface of the weld plate.
4. The interpass28 temperature is considered for pass-
II and pass-III to avoid hot cracking. The initial
temperature for pass-I is ambient i.e., is 30  C and
for the pass-II and pass-III was maintained about
200–250  C.
Experimentation
Arc welding process can be used welding of the thick
plate with single or multipass. GTA welding process
is used among the process which has less defects com-
pared with other processes. Welding of Austenitic
steels (SS316L) has attracted owing to the stringent
requirements in the industry like nuclear pressure ves-
sels, chemical plants and aeronautical sectors. In this
study, the butt joint with a single V-groove was used.
The dimension of the weld plates is 100 mm
60 mm5 mm, the multipass welding is carried out
(1) with three passes as displayed in Figure 2. The mate-
rial was filled with SS316L filler wire in the groove
designed with 2.4 mm diameter. The continues current
mode with a welding current of 135 amps, root gap of
2 mm and shielding gas as the argon flow rate of 12
LPM is chosen for all the pass during experimenta-
tion. The welding process is carried out with 0.79 kJ/
mm heat input for the pass 1, for the second pass the
heat input is 0.83 kJ/mm and for the final pass heat
input is 0.98 kJ/mm. To avoid the hot crack in the
weldment the interpass temperature of 200  C was
(2) maintained in between the pass. After the
4 Proc IMechE Part E: J Process Mechanical Engineering 0(0)

experimentation, the weldment was to cool in the air where n¼ the order of reflection beam, k is the wave-
at a room temperature of 32  C. The chemical com- length of the electrons, d¼ interplanar lattice spacing,
position, thermal and mechanical properties of the and h is on a crystal plane satisfies the Bragg
base material are given Tables 1 and 2. Equation. Residual stresses are measured at the var-
ious zone of weldment on the top surface on weld
Infrared thermography samples, for calculation32,33 of the residual stress,
the following equation (7) was used.
The temperature distribution29,30 can be collected
 
from the infrared thermography where it detects the m E
infrared energy emitted from the object, and it con- r/ ¼ (7)
d0 1 þ t
verts into temperature distribution. The output of the
thermal camera is in the form of the standard video
The data of d0 unstressed lattice spacing, d0, slope
signal, which shows the temperature distribution of
’m’ is measured by drawing lines between d spacing
the component. FLIR Thermocam was used for mea-
and sin2W, E and  are Young’s modulus and
suring the temperature and imager was range from
Poisson’s ratio of the materials.
20  C to 2000  C. The surface emissivity e of 0.7, is
used to calculate the surface temperature. The infra-
red thermography can give thermal images at any Results and discussion
point where on the surface of the plate by drawing
the line in the longitudinal or transverse direction.
Temperature analysis
These results were to analyse the heat generated at The nodal temperature distribution along the weld-
instance distance for understanding the real-time tem- ment for all passes are shown in Figure 4, Figure 4(a)
perature profile in the welding process. illustrates the SS-SS weldment for pass-1. It has been
that the maximum temperature of 1770  C and
Radiography: Weld quality
The weld joint obtained from the experimentation is
verified with visual and X-radiography technique and
weldment is from flaws. X-radiography analysis is
carried out using ASME Sec-VIII standards. The
weldment is free from internal defects like cracks,
blowholes, and porosity was not spotted from radi-
ography as displayed in Figure 3.

Residual stresses
Thermal stresses were developed during the welding
process which causes Residual stresses even after
removing the external load. The measurement was
carried out in transverse direction by using the
X-Ray Diffraction techniques31 as shown in equation
(6) using the Bragg angle.
Figure 3. Weld quality assessment. (a) Final weldment. (b)
nk ¼ 2dsinh (6) Radiography of the weldment.

Table 1. SS316L material chemical properties (% by mass).

Material Ni C Mn S Cu Si Cr P Mo

SS316L 12–18 0.03 2.00 0.030 – 1 16–18 0.045 2–3

Table 2. Thermal and mechanical properties of the base materials.

Coefficient of
Materials Thermal conductivity Density Specific heat Yield strength Poisson’s ratio thermal expansion

Units W/m K kg/m3 J/kg K MPa – –

SS316L 21.26 7817 572 193 0.3 15.6e6
Vemanaboina et al.
Figure 4. Temperature distribution in the SS316L to SS316L weldment. (a) Pass-1 Distribution. (b) Pass-2 Distribution. (c) Pass-3
Distribution.
minimum of 30  C, for pass-II the same weldment is
illustrated in Figure 4(b) and reported that the max-
imum temperature of 1881  C and min minimum tem-
perature of 200  C. The pass-III is reported to be
1740  C and a minimum temperature of 220  C. It
has been observed that the final maximum tempera-
ture in pass-II is higher than pass-III. The peak tem-
perature was witnessed at the weld zone as observed
in the experimental process. The heat is gathered at
the fusion zone and conduct in the transverse direc-
tion which leads to forms HAZ. It was observed that
the temperature distribution along the SS side was
widespread which attributes due to the presence of
large thermal conductivity.
Thermography analysis of SS316L to SS316L
Figure 5(a) to (c) shows the temperature distribution
of case-A. The pass-1 the temperatures are measured
in both longitudinal and transverse direction. The
line-1 (Li-1) shows the temperature distribution in
the welding direction and line-2 (Li-2) represents the
transverse direction. The temperatures are varying
from ambient temperature to a maximum of
1937  C at the fusion zone. The line-1 shows the tem-
perature is uncertain in the temperature distribution,
the weld zone the maximum peak is observed in the
5
weldment of 1663.8  C, and another peak also
observed of about 900  C of the filler rod. Figure 5
(b) shows the temperature of the pass-2 in the longi-
tudinal direction we can measure and understand the
temperature distribution of 2000  C at the weld zone
and filler rod of 1000  C in the transverse direction. In
line-2 the temperatures are varying from 200  C to
1758  C, and temperature peaks are disturbed due to
the interference of the welding torch. In pass-3 the
temperature of the weldment at the fusion zone is
1850  C, and in the line-2 the temperature is observed
that variation due to the electrode used is with a tem-
perature of 1200  C.
Residual stress
Figure 6 illustrates the residual stresses developed
across the transverse direction of the mentioned weld-
ments. The tensile residual stress spreading exposed at
the fusion zone and compressive stress far from it.
This is due to the expansion of the at the fusion
zone due to the presence of high temperature; howev-
er, this expansion is retarded by neighbouring base
metal region. The material experiences contraction
while cooling to maintain the original dimension of
the plate which generates the plastic deformation.
At HAZ, undergoes high-stress concentration to
6 Proc IMechE Part E: J Process Mechanical Engineering 0(0)

Figure 5. Infrared thermography analysis.

Figure 6. Residual stress SS316L weldments.

maintain the equilibrium between shrinkage action
of the base plate and the solidification of the
molten weld pool resulted in the generation of resid-
ual stresses.
Validation of simulation with experimentation
Temperatures. The final pass of heat input is the key
factor for analyzing the structure and thermal prop-
erties of the weldments for all the mentioned
Figure 7. Comparison of the temperature distribution of the
SS weldment.
combinations, therefore, this work is majorly interest-
ed to study the pass-III thermal and residual stresses
generated of the weldments. Figure 7 shows the pass-
III temperature distribution for the weldment both in
experimental and simulated work. The maximum
temperature was reported to be 1850  C and 1725  C
both the experimental and FEA study respectively.
Vemanaboina et al.
The variation may attribute to the presence of factors
such as convection and radiation effects. Further, it
has been observed that the thermal profiles were more
or less maintained symmetry along the fusion zone.
Residual stresses. The comparison of the residual stress
in the weldment for experimental and simulation
analysis are shown in Figure 8. The maximum tensile
stresses reported at the fusion zone of about 100 MPa
and 120 MPa for simulation and experimental analy-
sis respectively. Which the compressive stresses were
generated along the HAZ and further depression into
the base plate. The evaluated tensile and compressive
residual stresses are self-balanced within the struc-
ture.16 Authors had observed the maximum residual
stress in simulation studies this phenomenon is due to
the fixed welding time assumed for all the three passes
during welding. But whereas in the actual experimen-
tation procedure the welding time is varied due to
welding machine duty cycles and melting and deposi-
tion of filler wire. Lostado14 had also reported in his
work that any small differences between the welded
joints and the welded joints based on FEM can be
enlarged enormously in the presence of nonlinearities.
This influence and results in the dropping of structur-
al integrity.
The temperature and residual stresses are mea-
sured with infrared thermography and X-Ray diffrac-
tion are compared, the error % of each are given
supplementary Table 1. Thermal analysis shows
with an error of 7.24% and residual stresses are
16.66%. Due to the influential of heat input at
small areas had created the weld joint, the regions
near the weld line experience severe thermal cycles
and results with an increase in residual stresses. The
effect will reduce the life of the structure. In the cur-
rent study, the same was observed for welding simu-
lation results had seen the increase in error % of
residual stresses.
Figure 8. Comparison of Residual stresses in the SS316L
weldment.
7
Conclusion
This study has both FEA and experimental work of
multipass welding of SS316L with GTAW process.
The weldment was free from flaws and defects.
The temperatures are above melting points and give
good regular multipass welds. With the incorporation
of interpass temperatures between the second and
third pass, the hot cracking defects had overcome.
The assumed thermal and mechanical boundary con-
ditions show a good agreement of the results.
The peak temperatures in the weldment are at FZ
as measured by infrared thermography and simula-
tion values a variation of 7.24%. As expected, resid-
ual stresses distribution obtained from X-Ray
diffraction, were symmetric, bell-shaped, for the weld-
ment. The analysis of joints has maximum stress dis-
tributions within limits with the factor of safety of
1.025 assuring structural integrity. After the final
pass, residual stress by XRD measurements compared
with simulated ANSYS was 16.66% variations.
Further to decrease the temperature and residual
stress peaks, authors recommends, welding with
high heat input for the first pass for proper mixing
of base and filler materials and further decreases in
heat input for second and third passes by maintaining
interpass temperatures.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of
this article.
Funding
The author(s) received no financial support for the research,
authorship, and/or publication of this article.
ORCID iD
Harinadh Vemanaboina https://orcid.org/0000-0001-
9745-5463
Supplemental material
Supplemental material for this article is available online.
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