The Evolution of Residual Stress in Rib-Diaphragm Joints of Orthotropic Steel Decks Subjected to Thermal Cutting and Welding

Abstract

Residual stresses change the stress ratio of fluctuating stresses, hence seriously affect the fatigue life of orthotropic steel decks (OSDs) under traffic loading. Residual stress distributions near the U rib-diaphragm joints are very complicated and need to be investigated further. In this paper, a systematic method has been proposed for calculating the residual stress field in the joint of U rib and diaphragm due to thermal cutting and welding. Firstly, a mathematical model of cutting heat sources was established to predict the temperature field. Then, a numerical elastoplastic thermomechanical model was built to predict the residual stress evolutions in a diaphragm-rib joint through the whole fabrication process involving flame cutting and welding. Moreover, the simulated temperature contours at the fusion zone and the residual stress distributions in the rib-diaphragm joint were compared and verified against the experimental ones. The numerical results showed a great agreement with the experimental ones, indicating that the heat source model can be used to accurately predict the temperature field during flame cutting. Finally, the validated numerical model was utilized to conduct parametrical analyses on the effects of thermal processing rates, e.g., the cutting and welding speeds and on the residual stress distribution in the rib-diaphragm joint. The results indicate that a faster cutting speed and a slower welding speed can decrease the residual stress magnitude at the rib-diaphragm joints and reduce the high-stress zone near the diaphragm cutouts.

Rewelding Residual Stress of Fatigue Crack at U-Rib-to-Deck of an Orthotropic Steel Deck

“…In light of the advancements in computer technology, numerical simulation of the welding process has gained significant popularity. Kainuma [18], Puymbroeck et al [15], Xiong et al [19], and Gu et al [20] conducted a comprehensive investigation on the distribution of residual welding stress in orthotropic steel bridge decks. Their research has successfully validated the accuracy of numerical simulations through experimental analysis.…”

Investigation of the Residual Stress in a Multi-Pass T-Welded Joint Using Low Transformation Temperature Welding Wire

“…It is well known that fusion welding has been applied to a large number of engineering components. However, the non-uniform temperature distribution and constraint during the welding process engender residual stress in the welded joints [ 1 ]. Generally, tensile residual stress is detrimental to the fatigue strength, corrosion resistance and crack resistance of welded joints [ 2 , 3 , 4 ].…”

Numerical Simulation and Experimental Investigation of Temperature and Residual Stress Distributions in a Circular Patch Welded Structure

“…Since the occurrence of residual stresses and deformations due to welding is an inevitable phenomena, it is necessary to know their distribution as accurately as possible in order to take adequate measures already at the design stage to reduce them. For this purpose, it is reasonable to apply numerical methods in order to avoid expensive experimental measurements [10][11][12][13][14][15][16]. Regarding the above mentioned residual stresses and deformations caused by MAG welding, there are numerous numerical and experimental studies in the scientific literature for all important forms of welded structures, some of which are elaborated below.…”