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*Graduate Student, Department of Mechanica/ and Nuclear Engineering, Pennsylvania State University, University Park, Pennsy/vania, USA.
tAssociate Professor, Department of Mechanica/ and Nuclear Engineering, Pennsy/vania State University, University Park, Pennsylvania, USA.
Welding induces residual stresses in welded T-type stiffeners causing bowing (camber) distortion. Reducing the welding heat input or increasing the structural stiffness
reduces or eliminates bowing distortion. However, where the structure geometry and
weld size are fixed because of the design constraints, a transient differential heating
process is effective in reducing bowing distortion. This paper presents an experimental verification and demonstration of transient differential heating for minimizing welding-induced bowing distortion in welded stiffeners. Conventional welding is carried
out to demonstrate bowing distortion and establish a baseline case. Bowing distortion
is eliminated using transient differential heating during welding using the same welding conditions. Residual stress measurements are taken using the blind hole drilling
method, and a comparison of residual stresses for the baseline stiffener and for the
stiffener with transient differential heating is presented.
Introduction
IN THE shipbuilding industry, T-shaped stiffeners are manufactured by "cutting" or "stripping" from standard 1-beams. This
process has several disadvantages. First, considerable amount of
scrap is produced in the process of stripping. Second, flexibility in
the selection of the size and the material for the stiffener is restricted by the availability of the standard I-beams. To achieve
reduction in the overall weight of the ships, use of thinner section
components made of higher strength steel is desirable. Welding of
plates to fabricate stiffeners instead of stripping from standard
I-beams will lead to considerable savings by eliminating the scrap
parts. Furthermore, it will introduce flexibility in the selection of
the material and geometry of the stiffener.
Welding induces residual stresses, which result in distortion due
to buckling, bowing, and angular change, as discussed in detail by
Masubuchi (1980) (Fig. 1). In the case of the fabrication of T-type
stiffeners, the weld line does not coincide with the neutral axis of
the stiffener. When the weld line does not coincide with the neutral axis of the weld structure, longitudinal shrinkage of the weld
metal induces bending moments, resulting in longitudinal bending
distortion of the structure. Therefore, longitudinal bending distor-
MAY 2003
8756/1417103/1902-0076500.41/0
7
/
Buckling
Bowing
Fig. 1
Angular
Fig. 2
Many investigators (Nagraj Rao et al 1964, Dawes 1965, Alpsten & Tall 1970) studied residual stresses in welded shapes.
Dawes (1965) analyzed residual stresses in welded I-beam connections. Nagraj Rao et al (1964) studied residual stresses in
welded shapes. Sasayama et al (1955) investigated the longitudinal distortion of steel caused in fillet welding of T-bars in low
carbon steel.
Vanli and Michaleris (2001) investigated the distortion of
welded stiffeners with a particular emphasis on the prediction of
bowing, buckling, and angular distortion using the decoupled twoand three-dimensional finite element analysis technique developed
by Michaleris (Michaleris & DeBiccari 1996, Michaleris & DeBiccari 1997, Deo et al 2002). Bowing distortion was predicted in
large magnitude. Deo and Michaleris (2002) verified the two- and
three-dimensional finite element analysis technique for the stiffeners using experimental data. The bowing distortion in the stiffMAY 2003
77
cal tensioning (Masubuchi 1980, Terai 1978) and thermal tensioning (Ya et al 1977, Ya et al 1979, Michaleris & Sun 1996, Michaleris et al 1999) have been suggested for controlling welding
residual stress and hence distortion. These tensioning processes
involve generating tensile strain at the weld zone during welding
by either mechanical tensioning or by imposing a preset temperature gradient.
Mechanical tensioning has been studied in detail by the engineers at Kawasaki Heavy Industries (Terai 1978). In this method,
the p.ane! is stretqhed mechanically while it is being welded. When
the stretching load is released after welding, the plate shrinks and
t.h.ere is reduction in the amount of residual stress in the plate. This
method is effective when a thin sheet is welded to a rigid-framed
structure where the plate takes only tensile residual stresses,
whereas the frame takes compressive residual stresses after the
st.retching is removed. However, large forces are needed for
stretching l.arge panels, making the setup heavier. Furthermore,
industrial implementation of this method is impractical, because
the setup will become complex and very large forces will be
needed for large panels.
Effective application of longitudinal tensile strain in the web
plate will result in the elimination of bowing distortion. The longitudinal tensile strain can be applied by mechanical or thermal
tensioning. A mechanical tensioning method is impractical for
industrial implementation because it requires large forces and a
complex setup. Thermal tensioning is efficient, and industrial
implementation of this process is possible because of the localized
heating. Following the work of Deo and Michaleris (2002), a
scheme of side heating the web plate using a moving heat source
to induce tensile strain in the web plate while it is being welded is
proposed in this research (Fig. 6). This process of side heating will
be called transient differential heating. To enable inducing tensile
strain by heating, it is proposed that no tack welds should be
applied to allow the relative movement between the web plate and
flange. This will lead to expansion of the web during welding as
compared to the unheated flange. During cooling, the web will
contract, and therefore it will introduce a bowing distortion on the
stiffener in the negative direction (Fig. 3a) as compared to the
bowing distortion of the welding process (Fig. 3b). Once the transient differential heating is tuned to have equal magnitude but
opposite direction bowing direction, the two distortion modes will
cancel each other, and the stiffener will have zero bowing distortion (Fig. 3c).
Experimental verification of the proposed theory of reduction in
bowing distortion of stiffeners using transient differential heating
of the web plate is carried out in this work. The effect of different
side heating t.emperatures and tack welding schemes on the bowing distortion of the stiffener is studied, Welding conditions, specimen geometry, heating conditions, and the data acquisition
scheme are presented in detail for easy reproduction.
Experimental verification
A double fillet weld on a stiffene_r made up of ASTM A36 steel
is chosen for this investigation. Figure 4 and Table 1 illustrate the
geometry of the stiffener. Both the web and the flange are 4.76
mm (3/16in.) thick, 101.6 mm (4 in.) wide, and 1,219.2 mm (48 in.)
long. Applications of this stiffener in shipbuilding are discussed in
Michaleris and DeBiccari (1996, 1997). Furthermore, as demonstrated in Deo and Michaleris (2002), manufacturing this stiffener
78
MAY 2003
a)
b)
CONVENTIONAL WELDING
A"~
Web
tw
Flange
Bw
__
j
Y
Fig. 4
I__
tF
2B F
Dimensions of the T-type fillet welded stiffener
Welding conditions
Constant voltage metal inert gas welding is carried out. Carbon
steel filler metal bare (ER70S-6) welding electrode conforming to
AWS specification A5.18 (Cary 1998, American Welding Society
:2000) of I. 143 mm (0.045 in.) dia is used with a mixture of 75/25
argon and carbon dioxide shielding gas. The welding conditions
are set to give short circuiting transfer mode of the welding (Lincoln Electric 1998). Doublet fillet welds of size 3.97 mm (5/32 in.)
are carried out with dual torches by a gas metal arc welding
JOURNAL OF SHIP PRODUCTION
Table 1
Bw
101.6 mm (4 in.)
tw
2 B l.
101.6 mm (4 in.)
................ 7 ' 7 7 7 T r
Length
t~
4.76 mm
(Y,,
in.)
---
Experimental setup
The experimental arrangements and welding conditions for all
the cases are summarized in Table 2 and discussed in detail in this
section.
~4
WEL
Fig. 6
MAY 2003
Experimental setup for double fillet welding with side heating (dimensions in inches)
JOURNAL OF SHIP PRODUCTION
79
Table 2
Case
1
2
3
4
5
6
Weld
Travel Speed.
Size,
mm/min
mm (in.) Volts Amps
(in./min)
3.97 PAN
3.97 (%-9
3.97 (%2)
3.97 (%e)
3.97 (%9
3.97 (%:)
24
24
24
24
24
24
200
200
200
20(/
200
200
381 (15)
381 (15)
381 (15)
381 (15)
38I (15)
381 (15)
Whether
Side Heated
No
No
Yes (140 deg C)
Yes (140 deg C)
Yes (125 deg C)
Yes (160 deg C)
2:3S
Whether
Tack
Welded
Yes
No
Yes
No
No
No
" 51
Ssse 5
---
?ase
.......
"TP
--
, y"-.
........ ;;----.
..........
I0C
........2
E
qJ
50
.........
i .........
10
....5eld
Fig 7.
i .........
20
i .........
30
i .........
40
, .........
50
i .........
60
, .........
70
Pos:tion =(rnm)
, .........
80
, .........
93
17;:
: ' e e E:ae
Fig. 8
Case 5 and case 6: welding with side heating (125 deg C and
160 deg C) without tack welds
To study the tuning effect of the side heating temperature on
bowing distortion in a welded stiffener, welding is carried out
without tack welds on the stiffener with different heater settings.
The heater power is set in order to give 125 deg C peak temperature in case 5 and 160 deg C in case 6 at the unheated surface of
the web plate. The positioning of the heater and the welding conditions in case 5 and case 6 are identical to the previous case.
Figure 7 shows the temperature distribution across the stiffener
height.
MAY 2003
12
...........
24
i ...........
56
i ...........
48
i ...........
XCase 1
~Case 4
ACase 5
eCose 6
"~
Results
200
400
600
800
1000
! 200
1400
Position (ram)
Table 3 summarizes the results for all the cases. Figure 9 illustrates bowing distortion measurements taken using vernier calipers at five points along each stiffener. A graphic symbol is used
to denote the location and magnitude of each measurement. The
symbols are connected with straight lines. However, the stiffeners
have a smooth bowing distortion across the stiffener length, as
illustrated in the photographs of Figs. t0 to 13.
Fig. 9
span is 5.7 mm. The stiffener welded without tack welds in case
2 shows the same amount of bowing distortion (Figs. 9 and 10).
The residual stress readings are not taken because the bowing
distortion shows no change. Welding without tack welds does not
result in reduction of bowing distortion. Table 3 lists the amount
of bowing distortion in this case.
Case
Residual Stress
at Point
A in Fig. 4
(MPa)
Whether
Side Heated
Whether
Tack Welded
Whether
Bowing
Distortion
Present
1
2
3
4
5
6
130
*
*
35
*
*
No
No
Yes (140 deg C)
Yes (140 deg C)
Yes (125 deg C)
Yes (160 deg C)
Yes
No
Yes
No
No
No
Fig. 10
81
Fig. 13
Fig. 11 Bending of the stiffener web plate in case 3 after welding with
transient differential heating (140 deg C) of tack-welded specimen
Negative bowing of stiffener in case 6 after welding with transient differential heating (160 deg C)
MAY 2003
tack welds
Figure 13 shows the stiffener in case 6 after welding. The stiffener in this case bows in the opposite direction after welding with
side heating at 160 deg C. A light source is kept behind the welded
stiffener. The light rays passing from below the stiffener ends
illustrate the bowing distortion in the opposite direction. As opposed to the bowing in case 1 where the stiffener center was lifted
due to bowing, the stiffener ends are lifted due to bowing in this
case. Maximum bowing distortion occurs at the stiffener ends
instead of at the stiffener midspan. The amount of bowing distortion at the stiffener ends is 1.6 mm. Residual stress readings are
not taken because the bowing distortion is not eliminated. Overheating overcompensates for the welding bowing distortion and
leads to bowing in the opposite direction, which is not desired
JOURNAL OF SHIP PRODUCTION
Conclusions
This paper has presented a technique for the elimination of
welding-induced bowing distortion in welded T-type stiffeners by
transient differential heating using a moving heat source side heating the stiffener web plate. This resulted in the elimination of
bowing or longitudinal bending distortion.
Bowing distortion of large magnitude in welded T shapes
is caused by off neutral axis high residual tensile stress at the
welding zone.
Bowing distortion can be completely eliminated by transient differential heating using a moving heat source heating
the stiffener web plate during welding.
Relative longitudinal movement between the web and
flange due to heating during welding is needed for the application of transient differential heating. Therefore, tack welds
cannot be used.
Using the correct heater power is very important for the
elimination of bowing distortion. Overheating of the web will
lead to negative bowing, and underheating of the web plate will
result only in reduction o f b o w i n g distortion instead o f c o m plete elimination.
T h e r e is significant reduction in residual stress in the w e b
plate o f the stiffener w e l d e d w i t h o u t tack w e l d s and with side
h e a t i n g as c o m p a r e d to the stiffener w i t h o u t side heating.
T h e p r o c e s s o f transient differential heating can be easily
i m p l e m e n t e d in the industry for the fabrication o f stiffeners as
o p p o s e d to s t e a d y - s t a t e differential heating.
Acknowledgments
This work was funded by Office of Naval Research award
number N000140010645. Experimental work was made possible
by a donation of two Powerwave 455 STT welders by the Lincoln
Electric Company.
References
MAY 2003
V.P. 1979 Selection of the optimum fields for preheating plates before
welding. Art. Svarka, 5, 5-9.
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