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The austenite grain size (AGS) before decomposition is a crucial factor for the development of microstructure. However, this dependency is seldom discussed due to the difficulty of observing the grain growth of austenite during welding. In the current work, a grain growth algorithm is combined in a thermodynamics-based metallurgical model for the first time to analyse the influence of prior austenite grain size (pAGS). The phase volume fractions predicted at different cooling rates and pAGSs are compared with the experimental results of the continuous cooling transformation (CCT) diagram. To further investigate the influences of pAGS and microstructure on residual stress, experiments of bead-on-plate welding are conducted at three heat inputs, in which plates of S700 steel are operated by the arc welding process. The geometries after welding, chemical composition in the fusion zone (FZ) and the parameters of the double ellipsoidal heat source are calibrated using the software SimWeld. These geometries are imported to ABAQUS to create a finite element (FE) model. The validated metallurgical model together with the grain growth algorithm are implemented in the subroutine ABAMAIN to provide a thorough prediction of microstructure. With the knowledge of temperature and phase distributions, a coupled thermo-metallomechanical FE model is established to predict the residual stress distributions. The material properties are assigned by interpolating the individual phase property with its volume fraction. By comparing the results predicted by the model assuming constant pAGS, the influence of the pAGS on the residual stress is manifested. Moreover, simulations using overall material properties are also conducted. The stress distributions in the middle of plate surface are plotted along with the volume fractions of product phases to analyse the sensitivity of the residual stress to microstructure.

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