Structural and Physical Aspects of Civil Engineering, 2010

Analyze of the residual stresses induced by welding process of the

civil engineering structures with complex geometrical
configurations
Ioan Sorin Leoveanu, Daniel Taus, Valentin-Vasile Ungureanu
Transilvania University of Braov
Faculty of Civil Engineering, Civil Engineering Department
e-mail: leoveanui@yahoo.co.uk, tausdaniel@yahoo.com, vvungureanu@yahoo.com
Abstract
The Finite Elements Method numerical control of the welded structures designs, subjected to different loads is
more frequently nowadays. The present work proposes the estimation of the welded equivalent loading system
based on the residuals deflections caused by the welded processes. For the welded structures modelled by beams,
the work develops some exact algorithms based on displacements method and simplex linear transformation
algorithms method. For the more complex welded structures, processed using shells and bricks type finite
elements, are generated other chain of algorithms based on Greedy methods, for estimation of the optimum
welding equivalent loads and implicitly the welding processes parameters.
Key words: heat flow, welding processes, residual stresses, plasticity model, HAZ (Heat Affected Zone)
properties estimation
1 Introduction
The numerical estimation of residual stresses and strains, in the welded joint and structures is
one of the most complex processes [2 - 8]. In this paper there was considered the heat flow
analysis of welded joint, the metallurgical modelling of microstructure produced, including
crystallization of welding pool, the grain growth and solid-state transformation. The
mechanical property of HAZ and weld layers are established with more accuracy based on
those estimations. The heat flow is estimate using the volume finite method. The mechanical
proprieties of finite elements of welded area are estimate based on the microstructure included
in them.
Ioan Sorin Leoveanu, Daniel Taus and Valentin-Vasile Ungureanu


2 Physical model of residual stresses and strains numerical prediction
2.1 The heat flow analysis
It is making using the general equation:
L L z y x Rad Cv Arc
L
t
f
z
T
z y
T
y x
T
x
Q Q Q
t
T
C

+ + + =

) ( ) ( ) ( (1)
where:
Q
Cv
=h
cv
(T)(T-T
0
) heat loose by convection
Q
Rad
=(T) (T
4
-T
4
0
) heat loose by radiation
Q
Arc
heat of welding source
f fluid fraction
L
L
latent heat of liquid state
2.2 Heat source model
The heat source model is based on the MyhrGrong method [1, 2]. The heat source is divided
in many horizontal and vertical sources that are included in the welded area. This method
makes possible the modelling of different welded geometry (like key-hole) without using the
heat flux distribution. The establish of the points heat sources, in agreement with the welded
pool geometry coordinates, consist in the solving of the optimization problem.
Minimum ) (
1
S a
nP
s
s
I U q +

=
(2)
with conditions:
0
i
q (3a)
imposed
is
s
is
T T

(3b)
S a
s
s
I U q

(3c)
where:
[ ]
imposed
PN Pi P
imposed
P
T T T T ... ...
1
= - The value of temperature imposed on the weld
boundary
[ ]
T
i i i
z y x Pi = -The coordinates of check points of the weld boundary
[ ]
T
S S S s
z y x S = -The coordinates vector of source points
[ ]
nP S S
q q q Q ... ...
1
= -The unknown vector of sources point intensity
Cis
q
T
nP
s
s imposed
is
=
=
1
2
-The expression of the temperature in the check points


=

=
i
a
R V
i
nP
s
a
x V
i S
ext
S
e
R
e Cis
2
1
2
1
- For sources points on the surface, q
H

(
(

+ =


=

j k
a
R V
k
a
R V
j
nP
s
k S j S
a
x
S
V
e
R
e
R
e Cis
2 2
1
1 1
int
2
- For point sources inner, q
V

Structural and Physical Aspects of Civil Engineering, 2010


2 2 2
) 2 ( id z y x R
i
+ + = ;
2 2 2
) 2 ( + + = jd z y x R
j
;
2 2 2
) 2 ( + + + = kd z y x R
k

In the figures 1 and 2 are presented the heat source model from submerged weld and the
results of heat flow analyse.

Figure 1. The heat source model. Shape of key-hole welded pool and reduced points.


Figure 2. The temperature distribution in the welded pool and in the HAZ geometry.
3 The estimation of HAZ properties
The cooling process of HAZ make possible the analysis of microstructure properties for every
control volume based on the temperature history and CCT (Continuous Cooling
Transformation) diagram. The use of numerical particular analyse of metallurgical phase field
transformation, become more difficult even when the size grain orientation and composition
of the austenite grain and there boundary is known. One aspect of this difficulty consists in
the inclusions and in the lake of dislocation analyse or vacancy clusters position inside the
grain lattice. This unknown makes difficult the estimation of the position of germination
nuclei and their number. The establish of microstructure in solid state transformation, for a
given steel, control volume position and its time history is made based on the CCT diagram
estimation.
The martensite transformation can be modelled by the following equation:
)) ( exp( 1 ) ( T M b T p
S
= (4)
where: T < M
S,
M
S
is the martensite transformation temperature,
b is a proportion coefficient,
Ioan Sorin Leoveanu, Daniel Taus and Valentin-Vasile Ungureanu


p(T) is the proportion of phase field.
The ferrite-pearlite transformation is calculated using the Leblond general law:
) (
) (
) (
T f
T
p T p
dt
dp
ec
&

(5)
and the cases of transformation can be included in the general mechanisms:
phase 1 phase 2
phase 1 phase 2
The proportion of phases is:

2 1 2 1
1 p p p p & & = = + (6)
Transformation 1 2

1 2 2 12
12
2
1 12
12
2
12
2 2 1
12
2
12
2
12
2
2 1
) (
) ( 1
) (
) (
) (
) ( ) (
) (
) (
p p p
T
T p
p
T
T p
T
p p p T p
T
p T p
p p
ec ec
ec ec
& &
& &
= =

+
+
=

=


(7)
where:

) (
) ( 1
) (
) (
) (
) (
12
12
2
12
12
12
2
12
T
T p
T KP
T
T p
T K
ec
ec

=
=
(8)
and the variation of phases has the expressions:

2 12 1 12 2
2 12 1 12 1
) ( ) (
) ( ) (
p T KP p T K p
p T KP p T K p
=
+ =
&
&
(9)
Transformation 2 1

1 21 2 21 2
1 21 2 21 1
) ( ) (
) ( ) (
p T KP p T K p
p T KP p T K p
+ =
=
&
&
(10)
where

) (
) ( 1
) (
) (
) (
) (
21
21
1
21
21
21
1
21
T
T p
T KP
T
T p
T K
ec
ec

=
=
(11)
The transformations restrictions are:
For the transformation 1 2:
if
0
2 12 1 12 2
> = p KP p K p& (12)
then:
) (
12
2 2
T p p
ec
< (13)
For the transformation 2 1:
if
0
1 21 2 21 1
> = p KP p K p& (14)
then:
Structural and Physical Aspects of Civil Engineering, 2010


) (
21
1 1
T p p
ec
< (15)
The estimation of the mechanical properties for the material inside the volume control can be
done using the Table 1.

Table 1. Yield strength for the phase field
Phase Yield strength [MPa ]
Austenite (20C) 200 - 300
Ferrite - Pearlite (20C) 200 - 400
Bainite (20C) 600 - 700
Martensite (20C) > 1000
4 Plasticity model
In the plasticity model, it is analyze the effect of:
The volume changes imposed by the metallurgical transformation
tp

The plasticity imposed by the temperature and the yield strength modification in every
finite element of the HAZ,
cp
.
In the most used cases, the consideration of two phases that are in the heating and cooling
zone of the layer can give a good approximation of the transient stresses and strains [2, 3]:
One phase with low yield stress in the heating area of the welded joint (austenite);
A mixture of phases (ferrite, pearlite, martensite) in the cooling area, with yield
stress depending on temperature.
The yield stress is given by the mixture non-linear law:

C C C
p f p f
2 2 1 2
) ( )) ( 1 ( + = (16)
where:

C
1
- yield stress of austenite;

C
2
- yield stress of phases mixtures.
Using Von Mises stresses:
2 / 1
2
3
|

\
|
=
ji ij VM
S S (17)
if
VM
<
C
then
tp cp p
& & & + =
where:

2 2
1
2 1
2 2
1
2 1 2
1
2
) log(
3
) log(
) ( 3 ) ( ) 1 (
2
3
p p h S
T S p p S
E
p g p
C
VM
C
th
tp
C VM C
cp
& &
&
& &
|

\
|


=

(18)
E - Young module of phases (E
1
= E
2
)

i
- coefficient of expansion for phase i;
( )
V
V
th

3
2 1
2 1
- Volume modification during phase transformation
S - Stress tensor
Ioan Sorin Leoveanu, Daniel Taus and Valentin-Vasile Ungureanu


And for |

\
|
C
VM
h

it was used:
if
VM
/
C
0,5 then h(
VM
/
C
) = 1
if
VM
/
C
> 0,5 then |

\
|
+ = |

\
|
5 , 0 5 , 3 1
C
VM
C
VM
h

If
VM
=
C
then
S
tp cp p
= + =
&
& & & (19)
and
&
is calculate with the classical theory of plasticity.
5 Analytical Model Results
The model was used to verify the stresses induced by SMA (Shielded Metal Arc) welding
technology of a thick butt joint. The butt joint is in Y geometry, as in figure 3 and the stresses
maps for the longitudinal and transversal direction are shown in figures 4 and 5. The
experimental check of the stress and the calculate stresses are shown in figures 6 and 7.


Figure 3. Geometry of butt joint and the order of welded layers deposit

Figure 4. The transversal stresses distribution of butt welded

Figure 5. The longitudinal stresses distribution

Structural and Physical Aspects of Civil Engineering, 2010



Figure 6a. The transversal stresses computed
and measured map on the bottom face of the
joint.

Figure 6b. The transversal stresses computed
and measured map on the up face of the joint.

Figure 7a. The longitudinal stresses
computed and measured map on the bottom
face of the joint.

Figure 7b. The longitudinal stresses
computed and measured map on the up face
of the joint.
6 Conclusions on the analytical model
The proposed model for numerical estimation of residual stresses confirms the great
complexity of that phenomenon. The used model have a great accuracy for the analyse of heat
flow, and for the analyse of metallurgical phenomenon, such as heating and cooling
metallurgical transformations, grain growth of phases in the processes of heating, cooling and
constant temperature.
The temperature distribution given by heat flow, make possible the estimation of time
cooling between 500C and 800C or more exact the time within the materials is in the
transformations domain T
AC3
-T
MS
. The obtaining with biggest accuracy of the shape for
the HAZ area that gives good parameters technological was established.
Ioan Sorin Leoveanu, Daniel Taus and Valentin-Vasile Ungureanu


The estimation of the metallurgical phases is better even in quantitative, qualitative and
position in the HAZ and weld pool area.
The hardness distribution for the HAZ can be predicted with more accuracy.
The shape and the value of residual stresses in the transversal direction are in good
agreement with the experiments.
The shape of residual stresses in the longitudinal direction is good and in agreement with
experiments.
The value of residual stresses in the longitudinal direction gives errors from experiment.
The proposed plasticity model give good results and it will be used for futures
development.
The used analysis need a biggest CPU resources and in the future it must be change some
algorithms and methods for metallurgical simulation.
It is necessary to analyse with more accuracy the grains boundary chemical composition
and the effect of precipitate dissolution and germination for good predict of mechanical
properties.
Must know and predict the ferrite type and make difference in the bainite lower and upper
field.
It is necessary to make the analysis of germination in the solid-state transformation based
on the grain boundary geometry and their chemical composition.
Analysis of the precipitate stability and their distributions are necessary.
All the needed options can be make with lower computer resource by using the most
economic calculus method.
Based on these observations we can conclude that the approach numerical method, in this
stage, can not be used, with good results, for the welding optimization technology of
structures in the civil engineering area.
References
[1] Myhr, O.R, and Grong, O. Acta Metall. Mater., 1990, no. 38, p. 449-460
[2] Grong, O. Metallurgical Modelling of Welding. The Institute of Materials, Cambridge
University Press, 1992.
[3] Leoveanu, I.S., Zgur, Gh. Model de calcul cu elemente finite al matricii elasto-plastice n
cazul ZITM a cordoanelor de sudur, N.T.U.P.C., nr. VII. p. 301-307.
[4] Leoveanu, I.S. Determinarea forelor exercitate de cordoanele de sudur asupra seciunilor
formate din bare sudate, Buletinul AGIR, Vol.2, 1998
[5] Leoveanu, I.S., et al. Establishes of the Equivalent Longitudinal Forces products of the welded
joints and use them to the determination of the residual strains of the welded girders. Welding &
Joining Conference, Tel Aviv, 2000, p. 170-179
[6] Leoveanu, I.S., et al. The optimization model from the design and technology of the welded
beam structures, in condition of maximum energy absorbed, Welding & Joining Conference, Tel
Aviv, 2000, p.180-191
[7] Leoveanu, I.S, Zgur, Gh. Modelling the heat and fluid flow in the welding pool of high power
sources, Material Science Forum, No. 530, 2008, p. 443-446.
[8] Leoveanu, I.S. Numerical Modelling of transport phenomenon involved in the fusion-weld pool.
Revista Sudura, Nr. 1, 2010, p. 10-16.