Session: MF-03-01 Welding Residual Stress and Distortion Simulation and Measurement-1

Paper Number: 153266

153266 - An Experimental and Numerical Modelling for a Saw Mock-Up 

Abstract: 

This paper deals with the numerical welding simulation of a SAW mock-up. A specific mock-up joining two 18MND5 ferritic steel grade plates has been made. The narrow groove is filled by a SAW welding process using a multipass methodology (29 layers). To monitor the welding conditions as precisely as possible, temperature gradient within the mock-up base material, interpass temperature, and the outline evolution of the chamfer are recorded bead after bead during the manufacturing process.  The welding parameters (current, tension, welding time) are also recorded during the welding of each bead, as well as temperature evolution thanks to thermocouples. To complete the input data available for the simulation and assist its validation, extensive characterization, including hardness mapping, micrographs as well as residual stress measurements, were conducted.

The welding simulation is performed using the finite element software SYSWELD^TM. First a thermo-metallurgical simulation is performed (bead by bead following the welding sequence). The heat input is described by an equivalent heat source fitted thanks to experimental data (thermocouples, macrographs). The metallurgical transformations are also taken into account during the simulation. Then, a mechanical simulation is performed using the thermal and metallurgical state calculated previously to estimate the induced distortion and residual stresses of the process.

In this paper, the experimental mock-up and the experimental data are described in a first part. The numerical welding simulation and the assumptions used are explained in a second part. Then, in the last part, the experimental and simulation results are compared and discussed in term of temperature, metallurgical phases, distortions and residual stresses.

The comparisons show a good agreement between experimental measurement and numerical results, especially concerning residual stresses along cutting lines distribution.

Presenting Author: Sebastien Gallee FRAMATOME

Presenting Author Biography: Sébastien Gallée is a welding numerical simulation engineer with a 17 years career. He has worked for automotive, naval and nuclear industry and he is now a specialist for welding simulation at FRAMATOME in France.

Authors:

Sebastien Gallee FRAMATOME
Pierre-Olivier Barrioz FRAMATOME
Florence Gommez FRAMATOME
Alexandre Brosse FRAMATOME