Residual Stress and Deformation Analysis in Butt Welding on 6 mm SUS304 Steel with Jig Constraints Using Gas Metal Arc Welding

Abstract

This article proposes a novel method for analyzing residual stress and deformation in butt welding on 6 mm SUS304 stainless steel plates, using MSC.MARC, a commercial finite element method software, to find the best location for jig fixtures that will minimize welding deformation. Simulation and experimental studies show that a distance of 100 mm between the jig center and the welding bead center is best for inhibiting welding deformation when the jigs experience downward displacement at 0 mm on the steel plate; the total displacement is only about 1.1 mm in the case of a 300 × 250 × 6 mm SUS304 steel plate. In addition, a numerical model shows that four jigs with pitches of 200 mm can better reduce welding deformation than six jigs with pitches of 100 mm. The largest residual stress after welding occurs around the weld bead center, and the residual stress away from the welding bead center increases gradually when jigs have been applied on the steel plate to prevent deformation. The reaction force of the jigs on the steel plate has no further effect in reducing deformation. We conclude that commercially available jigs can inhibit deformation during the welding process.

Numerical prediction and experimental validation of temperature and residual stress distributions in buried‐arc welded thick plates

“…Costa et al 14 compared the welding-induced residual stresses of the cold-wire and conventional MAG welding processes by using X-ray diffraction and acoustic birefringence in their experimental study. Kung et al 15 proposed a novel method for analyzing residual stresses and deformations in butt-welded thin stainless plates using a numerical method to find the best location for jig fixtures that would minimize welding deformation.…”

“…Costa et al compared the welding‐induced residual stresses of the cold‐wire and conventional MAG welding processes by using X‐ray diffraction and acoustic birefringence in their experimental study. Kung et al proposed a novel method for analyzing residual stresses and deformations in butt‐welded thin stainless plates using a numerical method to find the best location for jig fixtures that would minimize welding deformation. Adamczuk et al experimentally analyzed the angular distortions in multipass welded thick steel plates using four different heat inputs that varied between 0.6 and 2.5 KJ/mm, and they proposed appropriate analytical solutions.…”

Numerical Analysis and Experiments of Butt Welding Deformations for Panel Block Assembly

“…Therefore, reduced usage of temporary piece, while maintaining a welding quality of hull block, is required. Interest in the optimization of butt joint welding has generated many analytical and experimental studies [3][4][5][6]. Furthermore, the studies have been made to reduce residual stresses and deformations of fillet weld joints.…”

“…Recently, efforts to precisely evaluate the residual stress and deformation of the butt-welded joint have been aided by finite element analysis, thanks to the development of increasingly more powerful computers. However, most of the research done has Interest in the optimization of butt joint welding has generated many analytical and experimental studies [3][4][5][6]. Furthermore, the studies have been made to reduce residual stresses and deformations of fillet weld joints.…”

Analytical Model for Angular Distortion in Multilayer Welding under Constraints

“…Ma et al [14] verified the deformation reduction according to the jig constraint position and pitch through experiments and theoretical analysis, and they addressed longitudinal and transverse shrinkage as well as angular distortion, which were significantly reduced. Kung et al [15] showed the deformation of SUS304 steel according to the number of jigs using finite element analysis and proposed the optimal location of jig fixtures. Park et al [16] derived the constraint coefficient through various welding experiments and analyses, obtaining the actual degree of constraint of a ship block and devising the optimal welding sequence.…”