Journal of Constructional Steel Research 102 (2014) 44–58

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Journal of Constructional Steel Research

FEA of residual stress in cruciform welded joint of hollow sectional tubes

Gurinder Singh Brar a,⁎, Chandra Shekhar Singh b
a
Department of Mechanical Engineering, Guru Nanak Dev Engineering College, Ludhiana 141006, Punjab, India
b
Anand Engineering College, Agra 282007, Uttar Pradesh, India

a r t i c l e i n f o a b s t r a c t

Article history: Welding is a joining process which is most widely used for permanent joining of two or more components.
Received 20 September 2013 Welding results in a very complex thermal cycle which results in irreversible elastic plastic deformation and
Accepted 27 June 2014 residual stresses in and around heat affected zone (HAZ). Residual stresses are produced in weldment due to
Available online xxxx
mismatching and non-uniform distributions of plastic and thermal strains. The existence of residual stresses in
structures affects the stress–strain relationship by lowering the proportional limit and thus reduces the buckling
Keywords:
Finite element analysis
strength. The purpose of the present study is to investigate the residual stresses in heat affected zone of cruciform
Cruciform welded joint welded joint of hollow sectional tubes. To precisely capture the residual stresses, computational methodology
Residual stress based on three-dimensional finite element model for the simulation of gas metal arc welding in cruciform welded
X-ray diffraction joint is presented. The complex phenomenon of welding is numerically solved by sequentially coupled transient,
non-linear thermo-mechanical analysis. X-ray diffraction experimental method is used to validate the finite
element model. The study further altered the welding parameters in order to reduce the residual stresses in
the joint thereby improving the strength of the joint.
© 2014 Elsevier Ltd. All rights reserved.

1. Introduction
Welding is a fabrication process in which two or more parts of same
or different materials are joined. The process is carried out by melting
the work pieces and adding a filler material to form a pool of molten
material that cools to become a joint. Fusion welding is a method that
involves a heat source, and often a filler material such as a consumable
electrode or a wire fed into the weld pool. During the welding processes,
residual stresses are produced in a structure as a consequence of local
plastic deformations introduced by inhomogeneous temperatures,
termed as thermal stresses, consisting of a rapid heating and subsequent
cooling phase. During the welding process, the weld area is heated up
sharply compared to the surrounding area and fused locally. The mate-
rial expands as a result of being heated. This expansion is restrained by
the surrounding cooler area, which gives rise to thermal stresses. The
thermal strains become so high that stresses enter the strain hardening
region. Consequently, the weld area is plastically hot-compressed and
residual stresses are developed.
Residual stress values can be derived from strain/deformation mea-
surements by different methods, broadly classified as destructive and
non-destructive. X-ray diffraction is a non-destructive measurement
method for measuring the residual stress in heat affected zone which
develops during welding process. In this technique strain is determined
⁎ Corresponding author.
E-mail addresses: brar_gurinder@gndec.ac.in, brar.gurinder@gmail.com (G.S. Brar),
cssbisht@gmail.com (C.S. Singh).
directly from measurements of atomic lattice spacing. Stresses are then
calculated from these strains.
Researchers have developed many techniques to predict welding
residual stresses. Intelligent tools and techniques have been applied
to predict residual stresses to meet the demands of automation in
industries. Dhas and Kumanan [1] addressed the development of finite
element model and neurohybrid models for the prediction of residual
stress in butt-welding. Yajiang et al. [2] controlled the weld heat input
to minimize the thermal stress to avoid welding cracks. Mochizuki
et al. [3] obtained the effect of the welding pass sequence on the residual
stress which shows that the residual stress of welds can be substantially
reduced with low transformation temperature welding material regard-
less of the welding pass sequence. The article also described an investi-
gation of welding distortion and residual stress generation by numerical
simulations of the temperature, microstructure and thermal stress
histories during welding with special consideration of the relationship
with phase transformation behavior.
Mousavi and Miresmaeili [4] investigated the effects of fluid flow,
plasticity, external constraint, joint design, groove configurations and
mechanical constraints on the residual stress distributions and on the
distortions produced during the TIG welding process for type 304
austenitic stainless steel using 3D finite element analyses and the results
were validated by X-ray diffraction techniques. The results showed that
the magnitudes of the transverse residual stresses increased about
threefold and the constrained weld structures had less distortion than
the non-constrained weld structures. Lee and Chang [5] developed a
sequentially coupled three-dimensional thermal–mechanical finite
element model to simulate the residual stress states in butt welds of

http://dx.doi.org/10.1016/j.jcsr.2014.06.011
0143-974X/© 2014 Elsevier Ltd. All rights reserved.
 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 45

Table 1
Chemical composition of mild steel (%wt).

C Si Mn S P Ni Cu Cr

0.16 0.03 0.32 0.05 0.2 0.01 0.01 0.01

Fig. 1. Cruciform joint.
thin-walled steel plate and the results demonstrated that welding resid-
ual stresses severely affected the fatigue crack growth rate in the welds,
i.e. the residual stresses could result in a reduction in the fatigue life of
the structure compared to that of the cracked body without the residual
stresses.
A computational technique based on finite element analysis was
developed by Dar et al. [6] for the s subsequent weld-induced residual
stress fields and distortion patterns in GTA welded thin-walled cylin-
ders of low carbon steel. A close correlation was developed successfully
with the experimental investigations. Along and near the weld line, a
high tensile and compressive axial residual stresses occurred on the
cylinder inner and outer surfaces, respectively. Huniti et al. [7] investi-
gated the variations of thermal and residual stresses inside a thin mild
steel plate during welding processes and presented a theoretical analy-
sis of the thermal and residual stresses inside a thin plate with a moving
heat source simulating arc welding. The study found that, as the weld
speed decreased, the temperature inside the plate increased and the
residual stresses reaching the yield limit were produced in wider areas
along the welded area. Zhang et al. [8] presented a validation of the
contour method by comparing it with diffraction measurements in a
MIG 2024-T351 aluminium alloy welded plate. The potential of the con-
tour method was demonstrated on aluminium alloy welded plate to
produce a full two-dimensional map of the longitudinal stress profile
across thickness.
Residual stress prediction and measurement was carried out on
welded tubular joint structures containing a lack of penetration, with
single-U weld groove and no groove, respectively by Barsoum [9]. The
lack of penetration size (root error) had a major influence on the fatigue
strength assessed from the root side in combination with compressive
residual stresses. Brar and Kumar [10] developed a three-dimensional
finite element model by making an approximate geometry of the butt
welded joint and then the finite element analysis was performed to
understand the complete nature of residual stresses in butt welded
joint of AISI 304 stainless steel plates by submerged arc welding (SAW),
manual metal arc welding (MMAG), gas metal arc welding (GMAW)
and gas tungsten arc welding (GTAW). It concluded that residual stresses
were lowest in case of GMAW and highest in SAW. Teng et al. [11]
described the thermal elasto-plastic analysis using finite element tech-
niques to analyze the thermo mechanical behavior and evaluated the
residual stresses and angular distortions of the T-joint in fillet welds.
With increasing flange thickness, the internal restraints were increased
and the tensile residual stress near the fillet weld toe increased. With
increasing penetration depth or heat input in fillet welding, the tensile
residual stress near the fillet weld toe decreased, and improved the
non-penetration defects.
In the present work, GMAW (fusion) welding is used to make the
cruciform joint of hollow sectional mild steel tubes and during welding
developed residual stresses is measured by X-ray diffraction and finite
element method. Cruciform welded joints are widely employed in
construction of steel bridges.
2. Joint preparation
A cruciform joint is prepared among three members, with two
members located approximately at right angle to third member in the
form of a sign + as shown in Fig. 1. IS 4923:1997 Yst 240 mild steel
hollow square sectional tube (49.5 mm × 49.5 mm × 2.0 mm) cut into
190 mm long and hollow rectangular sectional tube (50.0 mm ×
25.0 mm × 2.0 mm) cut into two pieces of 70 mm long are welded
in the form of cruciform joint by gas metal arc welding (as shown in
Fig. 2). The chemical composition of mild steel by (%wt) is given in
Table 1. The thermal and mechanical properties of IS 4923:1997 Yst
240 mild steel hollow sectional tubes used for the present study are
given in Table 2.
During welding process, heat is produced to join the work piece
which also raises the temperature in the joint. The raised temperature
affects the properties of the work piece. In the present work, the effects
of raised temperature on the properties of Yst 240 Mild Steel hollow
tubes are taken into account as shown in Fig. 3. As the temperature
increases up to the range of 650–750 °C, there is a decrease in the Young's
modulus and conductivity values and after that these values becomes
constant with the increase in temperature. With the increase in the
temperature up to the range of 650–750 °C, the values of Poisson
ratio, expansion and specific heat slightly increase and then become
constant with further increase in temperature. The value of yield stress
slightly decreases with the increase in temperature up to 500 °C
and after that rapidly decreases with the increase in temperature
up to 750 °C and then becomes constant with further increase in
temperature.
In the present work, the cut pieces of hollow tubes are connected
together by gas metal arc welding (GMAW), with one tube positioned
perpendicular to the other two tubes, thereby forming a cruciform
joint connection. The gas metal arc welding parameters (currently in

Table 2
Thermal and mechanical properties of mild steel hollow sectional tubes.

Property Value Property Value

11 2
Elastic modulus 2.1 × 10 N/m Yield strength 2.40 × 108 N/m2
Poisson ratio 0.29 Thermal expansion 1.3 × 10−5 k−1
co-efficient
Shear modulus 7.6 × 1010 N/m2 Thermal conductivity 44 w/m-k
Mass density 7860 kg/m3 Specific heat 620 J/kg/k
Tensile strength 410 × 106 N/m2 Elongation 15%
Fig. 2. Detailed geometry of cruciform joint (all dimensions in mm).
46 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58

7
Thermal Conducvity (10 w/m-k)
Poisson Rao
Elasc Modulus (10^11 N/m^2)
6 Thermal Expansion (10^-5 / k)
Yield Strength (10^8 N/m^2)
Specific Heat (10^2 J/kg/k)

MATERIAL PROPERTIES
5

0
0 200 400 600 800 1000 1200 1400
TEMPERATURE (0C)

Fig. 3. Effect of temperature on properties of mild steel hollow sectional tubes.

practice) adopted for preparing cruciform joint of hollow sectional
tubes are given in Table 3.
3. Strength investigation of cruciform joint
The failure of cruciform joint in different loading conditions was
investigated experimentally first. Then cruciform joint was modeled in
a finite element code and simulations were run for different loading
conditions. The results from this numerical technique were validated
by the experimental data.
3.1.3. Strength investigation of cruciform joint at load condition-2
The load condition-2 refers to testing when square sectioned hollow
tube constrained to move horizontally and load is applied vertically on
the shorter side of rectangular sectioned hollow tube of cruciform
Joint specimen as shown in Fig. 8. There is no damage seen in welding
joint and it shows good strength of cruciform joint but rectangular
tubes gets deformed in shape. Fig. 9 shows the result of the test at
139.4 kN load.
3.2. Numerical method

Welding simulations is one of the engineering techniques that can

3.1. Experimental investigation
be analyzed by the finite element method. By using the finite element
method it is possible to solve the mechanical, metallurgical and thermal
To know the failure behavior and strength of cruciform joint of
coupling associated with welding. In the present work, the cruciform
hollow tubes, Universal Testing Machine (UTM) is used for tension test
weld joint of mild steel hollow sectional tubes was modeled using a
and strength investigation of cruciform joint at different load condition.
commercially available finite element software.
The cruciform joint samples prepared were tested for three types of
To simplify the welding simulation, it is computationally efficient to
testing namely simple tensile test, load condition-1 (square sectioned
perform thermal and mechanical analyses separately. Fig. 10 shows the
hollow tube is fixed vertically and rectangular sectioned hollow tubes
meshed isometric view of the hollow sectional tubes that are to be
are under vertical load), and load condition-2 (square sectioned hollow
welded in the form of cruciform joint.
tube is fixed horizontally and rectangular sectioned hollow tubes are
The heat input during welding is modeled in finite element software
under vertical load).
by the equivalent heat input which includes body heat flux. The amount
of heat input, Q has been calculated by using empirical relation shown in
3.1.1. Tensile test Eq. (1). Typical welding parameter combination taken in this work for
The tensile test is used to determine the tensile strength of a cruci- GMAW technique is listed in Table 3.
form joint made by hollow tubes. To conduct tensile test, the prepared
cruciform joint sample was tested in tensile direction as shown in ηUI
Fig. 4. Experimentally it was determined that at 56.4 kN load, one side Q¼ ð1Þ
V
rectangular hollow tube of cruciform joint got separated with weld
bead from square hollow tube as shown in Fig. 5.

3.1.2. Strength investigation of cruciform joint at load condition-1

In load condition-1, square sectioned hollow tube is constrained to
move in the vertical direction and vertical load is applied on the longer
side of rectangular sectioned hollow tubes of cruciform joint sample as
shown in Fig. 6. A bend loading fixture was designed specifically for
this testing. The fixture provides the facility to test the cruciform work
piece samples in bend, while also providing boundary conditions. At
53.26 kN, some cracks are seen in fillet weld of cruciform joint as
shown in Fig. 7.

Table 3
GMAW parameters used for preparation of cruciform joint.

Voltage (U) (volts) Current (I) (amp.) Speed (V) (mm/s) Arc efficiency (η)

80 20 4.5 0.80
Fig. 4. Tensile test on cruciform joint.
 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 47

Fig. 5. Experimental result of tension test (load—56.4 kN).

Fig. 6. Cruciform joint testing at load condition-1. Fig. 8. Cruciform joint testing at load condition-2.

In the analysis, the moving heat source is simplified by assuming shown in Fig. 13. The maximum displacement of 0.29 mm is produced
that the welding arc stayed at an element with constant specific volume at 56.4 kN load.
heat flux, and then moved to the next element at the end of the load
step as the welding was finished. After finding the temperature distribu-
3.2.2. Strength investigation of cruciform joint at load condition-1
tion on cruciform welded joint, this temperature field is applied to the
For load condition-1, finite element simulations were carried out on
mechanical model as a body force with static loading to find the
similar lines as done in tensile test, except that samples were loaded in a
strength of joint by performing a non-linear analysis. Fig. 11 shows tem-
different configuration and have different boundary conditions as
perature field developed during welding of hollow sectional cruciform
shown in Fig. 14. FE results of load condition-1 for different loads are
joint by gas metal arc welding. The maximum temperature developed
shown in Fig. 15. Maximum displacement occurred at 53.26 kN load.
during welding of cruciform joint is 1944 °C.

3.2.3. Strength investigation of cruciform joint at load condition-2

3.2.1. Tensile test Finite element simulations were carried for load condition-2 on
Same boundary conditions as applied during the tensile test similar lines as for tensile and load condition-1 simulations, but with
performed on universal testing machine were used in finite element boundary conditions and load direction as shown in Fig. 16. FE results
code as shown in Fig. 12. FE results of tension test at different load are of load condition-2 at different load are shown in Fig. 17. The maximum

Fig. 7. Experimental result of load condition-1 (load—53.26 kN).

48 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58

Fig. 9. Experimental result of load condition-2 (load—139.4 kN).

Fig. 10. Meshed geometry of the cruciform joint.

deflection of 2.18 mm developed at 139.4 kN load in finite element

analysis for load condition-2.
Fig. 12. Boundary condition and load direction in tension test.

4. Residual Stresses in the cruciform joint

spacing of the diffraction planes, Bragg's law is employed. Bragg's law
4.1. Experimental method defines the condition for diffraction as shown in Eq. (2):

In measuring residual stress using X-ray diffraction (XRD), the strain nλ ¼ 2d sinθ ð2Þ
in the crystal lattice is measured and the associated residual stress is
determined from the elastic constants assuming a linear elastic distor- where n is the order of reflection (n = 1, 2, 3…), λ is wavelength, d is
tion of the appropriate crystal lattice plane. To obtain the interplanar interplanar spacing, and θ is angle of reflection. Eq. (2) is known as

Fig. 11. Temperature distribution in welded cruciform joint.

 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 49

(a) At 54.27 kN

(b) At 55.65 kN (c) At 56.4 kN

Fig. 13. FE analysis results of tension test.

Bragg's law and it forms the fundamental basis of X-ray diffraction of changes in the linear dimensions of the crystal lattice. The strain εΦψ
theory. Fig. 18 shows the axial system followed for the residual stress in the direction defined by the angles Φ and ψ is:
measurements.
If dΦψ is the interplanar spacing between the lattice planes measured Δd dΦΨ −d0
ε ΦΨ ¼ ¼ ð3Þ
in the direction defined by Φ and ψ, the strain can be expressed in terms d0 d0

where d0 is the stress-free lattice spacing.

The lattice spacing dΦψ, is a linear function of sin2ψ. The X-ray elastic
constants can be determined empirically, but the unstressed lattice
spacing, d0, is generally unknown. σΦ may be approximated to this
accuracy using Eq. (4):
   
E 1 ∂dΦΨ
σΦ ¼ ð4Þ
1 þ ν dΦ0 ∂ sin Ψ
2

where ν and E are Poisson's ratio and modulus of elasticity respectively

and dΦ0 is the intercept of the plot at sin2ψ = 0 and its value is given by
Eq. (5):
   
ν
dΦ0 ¼ d0 1− ðσ 1 þ σ 2 Þ ð5Þ
E

In the present work, residual stresses are measured using Panalytical

Fig. 14. Boundary condition and load direction at load condition-1. X'Pert MRD X-ray diffraction machine and a linear behavior of
50 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58

(a) At 52.24 kN Load

(b) At 52.81 kN Load (c) At 53.26 kN Load

Fig. 15. FE analysis results at load condition-1.

dΦψv/ssin2ψ pattern is obtained in the samples which show that there is
only normal stress in the plane of surface.
Residual stresses were determined experimentally by X-ray diffrac-
tion method by preparing two samples each at the following locations:
transverse direction in fillet welded square tube (ST1 and ST2), trans-
verse direction in fillet welded rectangular tube (RT1 and RT2), and
longitudinal direction along the weld bead in butt joint in square and
rectangular tubes (B1 and B2). Two samples from square tube (ST1
and ST2) when tested by X-ray diffraction method resulted in residual
stress values of 291.6 ± 63.8 MPa and 569.4 ± 108.5 as shown in
Fig. 19.
In a similar manner, performing X-ray diffraction to samples RT1 and
RT2, resulted in residual stress values of 409.5 ± 94.3 MPa and 470.7 ±
44.7 MPa respectively as shown in Fig. 20.
The cruciform joint of hollow sectional tubes also had butt weld joint
which also introduced the residual stress in the cruciform joint. The
residual stress in longitudinal direction along the weld bead was also
measured by X-ray diffraction method in two samples from butt joint
(B1 and B2) made by square and rectangular tubes combination as
shown in Fig. 21. The values of residual stresses in two samples from
butt joint (B1 and B2) along the weld bead were 621.1 ± 40.7 MPa
and 541.2 ± 17.9 MPa respectively.

4.2. Numerical analysis

A commercially available finite element software was used to simu-

late the welding operation of cruciform joint. The joint was first exposed
to welding temperature. When the computation of the temperature
history during welding is completed then this temperature field is
Fig. 16. Boundary condition and load direction at load condition-2. applied to the mechanical model as a body force to perform the residual
 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 51

(a) At 82.56 kN Load

(b) At 100.98 kN Load (c) At 139.4 kN Load

Fig. 17. FE analysis results at load condition-2.

stress analysis. After assigning the material properties and specifying
the boundary conditions, thermal load is applied from previous thermal
analysis to measure the residual stress by performing Non-linear analysis.
After the analysis, the post-processing steps are used to view the results.
An overview of finite element modeling of welding residual stresses is
shown in Fig. 22.
The temperature field developed during welding of hollow sectional
cruciform joint by gas metal arc welding is shown in Fig. 11 which
shows that the maximum temperature developed during welding is
1944 °C. For determining the residual stress in the joint, the tempera-
ture field is applied to the mechanical model as a body force for
performing a non-linear analysis. Fig. 23 shows that the residual stress
developed in the cruciform joint in different directions.

5. Validation of finite element model

A finite element model was developed to determine the perfor-

mance of cruciform joint in static loading and residual stresses in the
joint. The developed finite element model needs to be validated by com-
paring the results against the experimentally determined values.

5.1. Static strength

In experimental testing, cruciform joints were subjected to loads

Fig. 18. Plane-stress elastic model and axial system.
until it actually fails. The failed pieces were then studied and compared
to determine the effect of load on cruciform joint. The results show that
in general a good agreement exists between the experimental and finite
element method for the present research work. The slight difference be-
tween the finite element results and experimental data can be attribut-
ed to many sources of error. These errors can be inaccuracy in material
52 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58

ST-1 ST-2
Fig. 19. Residual stress value obtained by sin2ψ method in samples ST1 and ST2.

RT1 RT2
Fig. 20. Residual stress value obtained by sin2ψ method in samples RT1 and RT2.

properties, inaccurate heat effected zone and unmatched temperature provide slightly higher values of displacement as compared to finite
history. element results for a given load as can be seen in Fig. 24.

5.1.1. Tensile test 5.1.2. Load condition-1

The experimental tensile test was conducted on five numbers Fig. 25 shows the results of the experimental test at load condition-1
of joints and then results were averaged. Experimental test readings and results predicted by finite element modeling. A good agreement

B1 B2
Fig. 21. Residual stress obtained by sin2ψ method in samples B1 and B2.
 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 53

Fig. 22. Finite element modeling of residual stresses in welding process.

exists between results from both the methods. It is observed that with 5.1.3. Load condition-2
an increase in the applied load, there is a better agreement between Fig. 26 shows the comparison of load verses displacement curve
the finite element and experimental results. obtained from the finite element and experimental test at load

(a) Residual stress in X-direction (b) Residual stress in Y-direction

(c) Residual stress in Z-direction

Fig. 23. Residual stress developed in the cruciform joint in FE analysis.
54 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58

Fig. 24. Load–displacement curve from experimental and finite element tensile test.

Fig. 25. Load–displacement curve from experimental and finite element method at load condition-1.

condition-2. The general agreement between the finite element and the
experimental results is satisfying for this load condition.
5.2. Residual stresses
Residual stresses calculated by X-ray diffraction (XRD) method were
used to validate the finite element results. Figs. 27–28 show the predict-
ed and the measured residual stress values by finite element method
and XRD method in different weld joint samples of cruciform joint.
The calculated residual stresses by finite element method are in good
agreement with the experimentally obtained values. The difference
between the finite element results and experimental data can be attrib-
uted to some sources of error. These errors can be unmatched
temperature history, inaccurate heat effected zone and inaccuracy in
material properties. The comparative graphs of XRD method and finite
element method of samples ST1 and ST2 (i.e. transverse direction in
fillet welded square tube) are shown in Fig. 27.
In a similar manner, a comparison of residual stresses calculated
by finite element method with XRD method is shown for two samples
from rectangular tube (RT1 and RT2) used in fillet weld in
Fig. 28(a) and (b). The residual stresses calculated in longitudinal
direction along the weld bead by XRD method and finite element

Fig. 26. Load–displacement curve from experimental and finite element method at load condition-2.
 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 55

(a) ST1 (b) ST2

Fig. 27. Residual stress obtained by XRD and FE method in samples.

(a) RT1 (b) RT2

(c) B1 (d) B2
Fig. 28. Residual stress obtained by XRD and FE method in various samples.

method, in two samples from butt joint (B1 and B2) made by square and sectional tubes by GMAW. Table 4 gives two combinations of welding
rectangular tubes combination are shown in Fig. 28(c) and (d). Even parameters, the parameters currently in practice and the optimized
though there are slight differences among the results, a reasonably parameters. It can be noted that a decrease in voltage and an increase
good agreement exists between the cases. in speed reduce the amount of heat input in the joint, thus reducing

6. Optimization of welding parameters

Table 4
After the finite element model was validated, as agreement was Welding parameter combination for reduction of residual stress.
found between the results from finite element analysis and experimen-
S. no. Parameters Voltage (U) Current (I) Speed (V) Arc efficiency
tal determination, the model was used to reduce residual stress levels in
(volt) (amp.) (mm/s) (η)
the cruciform joint. Optimization of welding parameters is required to
minimize residual stress in the joint. Different combinations of welding 1 In practice 80 20 4.5 0.80
2 Optimized 70 20 5.5 0.80
parameters were studied which can be used in joining the hollow
56 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58
Fig. 29. Load–displacement curve for parameter combinations 1 and 2 in tension test.
the residual stress. But these changes in parameters can affect the
strength of joint which needs to further explored.
The amount of heat input, Q is calculated by using empirical relation
shown in Eq. (1). The minimum heat inputs values are obtained at opti-
mized parameter combinations. These heat input values are modeled by
the equivalent heat input which includes body heat flux. The maximum
temperature obtained is 1398 °C.
6.1. Effect of optimized welding parameters on joint strength
The developed finite element model was used to compare the weld
joint strength obtained when welded by currently used parameters and
optimized welding parameters. Tensile test and different load condition
tests were performed to find the effect of reduced residual stress on
weld joint strength.
6.1.1. Effect on tensile strength
The calculated results of tensile test by finite element analysis at pa-
rameter combination 2 (optimized parameters) were compared to the
previous results of tensile test obtained from parameter combination
1 (currently used parameters). Fig. 29 shows that the maximum dis-
placement is produced at load 56.4 kN in both the cases. Comparison
also shows that displacement decreases with decrement in the residual
stresses while the applied loads are same during tension test in both the
cases of finite element analysis.
Fig. 30. Load–displacement curve of finite element analysis for parameter combinations 1 and 2 at load condition-1.
6.1.2. Effect on strength in load condition-1
The results of the finite element analysis at parameter combination 2
(optimized parameters) were compared to the results predicted by
using parameter combination 1 (currently used parameters) as shown
in Fig. 30. The result shows that the maximum deflection of cruciform
joint is 3.197 mm and 3.21 mm by finite element analysis at parameters
combinations 2 and 1 respectively, developed at load 53.26 kN.
6.1.3. Effect on strength in load condition-2
Fig. 31 shows the comparison of results obtains at load condition-2
by finite element analysis at optimized parameters and the currently
used parameters. The maximum deflection is 2.19 mm and 2.18 mm
obtained by finite element analysis for parameter combinations 2
and 1 respectively, developed at load 139.4 kN, there is no change in dis-
placement during the load condition-2.
6.2. Effect of optimized welding parameters on residual stress
The finite element analysis results of residual stress at welding
parameter combinations 1 and 2 in samples from square tube (ST1
and ST2) used in fillet weld, in samples from rectangular tube (RT1
and RT2) used in fillet weld, and in longitudinal direction along the
weld bead from butt joint (B-1 and B-2) made by square and rectangular
tubes are shown in Fig. 32. In all the cases it can be clearly seen that
residual stress decreases by 50–100 MPa, thus considerably reducing
residual stress value and increasing life of the joint.
 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58 57

Fig. 31. Load–displacement curve of finite element analysis for parameter combinations 1 and 2 at load condition-2.

(a) ST1 (b) ST2

(c) RT1 (d) RT2

(e) B1 (f) B2
Fig. 32. Residual stress by finite element analysis at parameter combinations 1 and 2.
58 G.S. Brar, C.S. Singh / Journal of Constructional Steel Research 102 (2014) 44–58
7. Conclusion
In this study, residual stress prediction was carried out on cruciform
welded joint of tubular sections. On the basis of results and discussion,
the following conclusions to be drawn are as follows:
• Residual stresses are high around the heat affected zone (HAZ) and
decrease with the distance from the centre of the heat source.
• The finite element analysis results have good agreement with the
results obtained by X-ray diffraction (XRD) method.
• When heat input increases, it also increases residual stress and when
welding speed increases, it decreases residual stress.
• The temperature distribution increases when weld speed decreases and
the residual stresses are produced in wider areas along the welded area.
• Experimental and finite element method results are in a good agree-
ment during the tension test and at different load conditions.
• By reduction in residual stress through change in input parameters,
displacement decreases during tension test and at load condition-1.
• The tensile strength of cruciform joint is improved by approximately
24.13% due to reduction of residual stress in the heat affected zone
by change in input parameters of GMAW.
• The strength of cruciform joint at load condition-1 also improves by
approximately 0.404% with change in welding parameters. But at
load condition-2, there is no such change in strength.
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