Abstract
Austenitic stainless steel, also known as SUS304, has a wide industrial application. The resultant residual stresses and deformation due to arc welding play a critical role in an in-service SUS04 part failure. Various experimental studies have been presented to predict residual stresses and part deformation. However, these techniques are expensive and time-consuming owing to the trial-and-error approach, limiting their application to industrial applications. Based on the emergent need, this study introduces two simulation models based on analytical and FEM techniques for thermal distribution and residual stress estimation. The experimentally calibrated models results have been implemented for SUS304 multi-pass arc welding. For the analytical simulation framework, a thermal model by considering the arc torch energy attenuation has been solved and provided as an input to the residual stress distribution model solved using Green's function technique. For FEM, a thermo-mechanical coupled model has been proposed and solved using the symmetrical technique. A close correlation has been identified among the analytical, FEM, and experimental techniques. It was found that during the second welding pass, a significant increase in the peak temperature was observed due to elevated arc-material interaction, leading to an expanded heat-affected zone and melt pool. Residual stress analysis highlighted the crucial role of thermal gradient and cooling mechanisms in generating stress within the weld region, which is essential for material strength assessment and failure prediction. This study offers a comprehensive understanding of the thermal and residual stress behaviors in multi-pass arc welding of SUS304 stainless steel bulk plates and can be applied to arc-based additive manufacturing processes.
Recommended Citation
M. A. Mahmood et al., "Analytical and Fem Models for Thermal Analysis and Residual Stresses using Wire Arc-Based Welding and Additive Manufacturing of SUS304," International Journal of Advanced Manufacturing Technology, vol. 133, no. 5 thru 6, pp. 2363 - 2380, Springer, Jul 2024.
The definitive version is available at https://doi.org/10.1007/s00170-024-13797-0
Department(s)
Mechanical and Aerospace Engineering
Keywords and Phrases
Analytical framework; Austenitic stainless steel SUS304; FEM analysis; Multi-pass arc welding; Residual stresses
International Standard Serial Number (ISSN)
1433-3015; 0268-3768
Document Type
Article - Journal
Document Version
Citation
File Type
text
Language(s)
English
Rights
© 2024 Springer, All rights reserved.
Publication Date
01 Jul 2024
Comments
Intelligent Systems Center, Grant CMMI-1625736