Thermal and Stress Analysis in Butt, T-shaped and Tubular Joints in the Welding Process of Dissimilar Parts

Subject Areas :

Adel Tavabe ¹ , Behdad Jahanbeen ² , Seyed Mohammad Reza Nazemosadat ³ , Ahmad Afsari ⁴

1 - Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
2 - Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
3 - Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
4 - Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran

Received: 2023-04-02 Accepted : 2023-05-14 Published : 2023-02-01

Keywords: Finite Element Method, Residual stress, Welding Process, Thermal analysis, Dissimilar Joints,

Abstract :

Connecting parts through welding as permanent connections can play an important role in various industries. Despite the favorable load-bearing capabilities of joints resulting from welding dissimilar parts, they have some limitations that need to be identified and checked to optimize their use. One of the limitations is the behavior of parts under thermal stresses caused by the welding process. Thus, it is important to consider the welding conditions of the dissimilar parts in the contact area of the electrode and the welding seam, as this can significantly affect the mechanical performance of the welds. The research conducted in this study involved using the electric welding method with non-consumable tungsten electrodes under shielding gas (TIG) to connect aluminum and carbon steel parts. Ansys software was utilized to investigate the effect of thermal stress in the welding process for different joints. To ensure accuracy, parts were welded together practically under similar conditions, and the results obtained were compared with the results of the modeled method. First, the behavior of a steel sheet under the butt and Tee Joint and then the role of various factors on welding performance were investigated by modeling the process for a pipe in different conditions. Finally, due to the significant role of T-shaped joints in various industries, heat distribution, behavior, and stress analysis were investigated.

References:

[1] Parmar, R. S. 2001. Welding processes and technology. Khanna Publishers, India.

[2] Masubuchi, K. 2013. Analysis of welded structures: residual stresses, distortion, and their consequences. Elsevier.

[3] Marques, E.S., Silva, F.J. and Pereira, A.B. 2020. Comparison of finite element methods in fusion welding processes-A review. Metals. 10(1):75.

[4] Seok, C.S., Suh, M.W. and Park, J.H. 1999. Investigation of welding residual stress of high tensile steel by finite element method and experiment. KSME International Journal.13:879-885.

[5] Tschirner, P., Hillers, B. and Graser, A. 2002. A concept for the application of augmented reality in manual gas metal arc welding. International Symposium on Mixed and Augmented Reality, IEEE.

[6] Akbari, D. 2017. Effect of edge preparation on residual stress of welding in dissimilar joints. Modares Mechanical Engineering. 17(7):307-315.

[7] Nakhodchi, S., Akbari Iraj, S. and Rezazadeh, H. 2014. Numerical and experimental study of temperature and residual stress in multi-pass welding of two stainless steel plates having different thicknesses. Modares Mechanical Engineering. 14(9): 81-89.

 [8] Bellmann, J., Schettler, S., Schulze, S., Wagner, M., Standfuss, J., Zimmermann, M., Beyer, E. and Leyens, C. 2021. Improving and monitoring the magnetic pulse welding process between dissimilar metals. Welding in the World. 65:199-209.

[9] Teng, T.L., Fung, C.P., Chang, P.H. and Yang, W.C. 2001. Analysis of residual stresses and distortions in T-joint fillet welds. International Journal of Pressure Vessels and Piping, 78(8), pp.523-538.

[10] Perić, M., Tonković, Z., Rodić, A., Surjak, M., Garašić, I., Boras, I. and Švaić, S. 2014. Numerical analysis and experimental investigation of welding residual stresses and distortions in a T-joint fillet weld. Materials & Design. 53:1052-1063.

[11] Zhang, W., Kim, C.H. and DebRoy, T. 2004. Heat and fluid flow in complex joints during gas metal arc welding-part I: numerical model of fillet welding. Journal of applied physics. 95(9):5210-5219.

 [12] Ghassemi, H. 2011. Study of welding temperature history by dual reciprocity boundary element method. Modares Mechanical Engineering. 11(3):95-102.

[13] Majzoobi, G.H., Seifi, R. and Ali-akbar, S. 2012. Experimental and numerical study of temperature distribution and determination of residual stresses due to welding of plates. Journal of Modeling in Engineering. 9 (27): 49-59.

[14] He, B. 2005. Computer modeling of weld joint microstructure and residual stresses. PhD Thesis. Carleton University.