Verification of Welding Simulations

with Measurement
Workshop:
Current State and Future of Neutron Stress Diffractometers
January 10-12, 2012, Sydney (Lucas Heights)

Our Major Collaborators in Welding Simulations

British Energy EDF

European Network on Neutron

Techniques (NeT)
AREVA
Rolls-Royce
SERCO
Etc..

Developing expertise for future power generation technology including Gen IV

Process of determining and verifying

residual stress using simulation and
measurement
-ABAQUS Weld Simulation Model
- Thermal Analysis

FE Modelling

- Mechanical Analysis
Co dependant

- Neutron Diffraction
- Synchrotron Diffraction
- X-ray diffraction

Verification

- Contour deflections
- Deep hole drilling

NeT Task Group work

round robins
TG4
3 pass weld
316L (Austenitic -no phase transformation)

TG5
Autogenous weld
AS508 (Ferritic -phase transformation)

TG4
3-Pass automated TIG Slot Weld

pass 1

pass 2

pass 3

Specimen

Fusion boundary macrographs from weld trials

ABAQUS Model

Welding Parameters
-for each pass

Volts
Amps
Run speed
Weaving?
Wire feed rate
Interpass temperature

Thermal Model: FEAT-WMT

Gaussian Ellipsoidal Heat Source (with weaving)
Micrographs

FEAT-WMT

AMPS = 220A
VOLTS = 10V
EFFICIENCY =
0.73%
SPEED = 1.27mm/s

100%, Melted

29.16mm2

AMPS = 195A
VOLTS = 10V
EFFICIENCY =
0.72%
SPEED = 1.27mm/s

30.22mm2

AMPS = 195A
VOLTS = 10V
EFFICIENCY =
0.71%
SPEED = 1.27mm/s

Pass 1

101% Melted

Pass 3

Pass 2

28.81mm2

100%, Melted

Thermal Model, MT: ABAQUS

Pass 1

Thermocouples: TC9

Pass 1

Pass 3

TC9

Welding Thermal Simulation (~18 hours)

ABAQUS Model

accumulated fusion zone of PASS1,

PASS2 and PASS3, isotherm 1400C

elements associated with the weld metal

Mechanical Analysis -Material Properties

Elastic Modulus
Thermal Expansion
Strain Hardening properties
Annealing temperature
all temperature dependant!

Material Testing
Cyclic Hardening
20, 200, 400, 600, 700, 800 C
600deg 2.5%strain 0.04%/s
400

300

Stress (MPa)

200

100

-100

-200

-300

-400
-1.5

-1

-0.5

Strain (%)

0.5

1.5

Material Models -cyclic hardening

Chaboche mixed hardening law
(isotropic/kinematic)

Welding Mechanical Simulation (~5 days)

TG5 -Autogenous TIG beam weld

- SA508 Gr.3 Cl.1 (Ferritic steel)
- Two specimens tested with
varying torch speeds:
fast weld => 300mm/min
slow weld => 75mm/min
Run-on and run-off plates only
on fast weld
Pre-heat (150C) was applied to
slow weld sample only

2D Finite Element Model

Fast Weld

Slow Weld

Thermal Analysis - Fusion Zone

Fast Weld

observation

FEAT prediction

Slow Weld

observation

FEAT prediction

(1) Isothermal Phase Nucleation

- Semi-empirical formulae developed by Li et
al. (1998), modified from Kirkaldy and
Venugopalan (1984).

TTT diagram
900

800

F(C,Mn,Si, Ni,Cr,Mo,G )
S(X)
n
T exp ( Q/RT)

- The model describes the time () required for

a given transformation to reach a fraction of
completion X at constant temperature T.

700

Tem perature [C ]

(X,T)

F
600

A
500

B
400

M
- F is a function to the steel composition and the ASTM grain size 300 -1
10
number G, T is the amount of undercooling, Q is the activation
energy for the diffusion reaction, R is the gas constant, n is an
empirical constant based on the effective diffusion mechanism, and
S(X) is a sigmoidal function defining the reaction rate.

10

10

10

10

Time [sec]

10

10

10

(1) Anisothermal Phase Nucleation

CCT diagram, Tpeak = 1450C

- To accurately predict anisothermal phase

nucleation, an additive rule first proposed by
Scheil (1935) and Avrami (1940) is used.

900

103 C/s

- The time t for phase nucleation to occur is

reached when:

101 C/s

10-1 C/s

800

dt
0 ( X , T ) 1

Tem perature [C ]

700

F
600

A
500

- Anisothermal phase nucleation occurs over a

transient thermal history.

400

M
300
-1
10

10

- For nucleation, X is set to 0.01 in this study. When applied to FE analysis, the predicted
anisothermal reaction is represented by the sum of a series of isothermal events occurring over
short discrete time increments, using the instantaneous temperature at each increment.

10

10

10

Time [sec]

10

10

10

(2) Austenite Grain Growth

CCT diagram, Tpeak = 1450C

- Empirical formula developed by Ikawa et al.

(1977) describes the austenite growth kinetics
in ferritic steels using the following formulation
for a given increment of time t:

A 2.969 10

15

- Can result in significant delay in phase

nucleation, depending on peak temperature

800

Constant Grain Size

Variable Grain Size

700

Tem perature [C ]

D 4 D04 A t e 69300/ T

900

F
600

500

B
400

M
300
-1
0
10
10
- D, D0 represent the final and initial austenite grain size in mm, respectively. The approach was found
to be consistent for a wide range of ferritic steels, and assumed an initial grain diameter of 0.015 mm at
1000 C. The ASTM grain size number is determined from the predicted diameter and this is updated in
the nucleation equation.

10

10

10

Time [sec]

10

10

10

(3) Phase Growth Kinetics

- Martensitic growth kinetics is assumed instantaneous once temperature drops below the martensite
start temperature (Ms) based on Kung and Rayment (1982):

M S 539 423C 30.4 Mn 17.7 Ni 12.1Cr 7.5Mo 10Co 7.5Si

- Diffusional growth kinetics (bainite, ferrite, pearlite) are predicted using a modified Leblond and Devaux
(1984) formalism:
t

dt
z
(1.00, T ) (0.01, T )
t0

- (1.00, T) is the time when 100% of the

phase is created, (0.01, T) is the time of phase
nucleation

total time (isothermal) from phase nucleation to completion (100%)

- Original implementation required fit to empirical data, modification allows for growth to be based on
sigmoidal growth assumption from isotropic kinetics.

Microstructure - Observation

Fast Weld

Slow Weld

Microstructure - Predictions
Fast Weld

ferrite/austenite
on heating

bainite/martensite
on cooling

Slow Weld

ferrite/austenite
on heating

bainite/martensite
on cooling

Microhardness - Predictions
Fast Weld

Microhardness - Predictions
Slow Weld

3D Finite Element Model

TG5 3D Slow - Thermal Analysis

TG5 3D Slow - Thermal Analysis

TG5 3D Slow - Microstructure

steady-state

Parent Metal Volume Fraction

TG5 3D Slow - Microstructure

steady-state

Martensite Volume Fraction

TG5 3D Slow - Microstructure

steady-state

Bainite Volume Fraction

TG5 3D Slow - Residual Stress

No Specific Phase Yielding included !!!
- coupled analysis
- SA508 material properties only

- We have more work to do!!

- But how would you know without
the measurements

Why all the effort?

Techniques developed and verified on simple
geometries can be used on more complex real
welds

Weld Simulation Case Study: Stress

Corrosion Cracking in Pressurised Water
Reactor Welds

Since 2000, 19 cracks found at dissimilar metal welds

Engineering solution is full structural weld overlays
Structural Integrity assessment needs weld stresses
ANSTO working with Nuclear Regulatory Commission (US)
and British Energy-EDF (UK) to develop validated weld
modelling of dissimilar metal welds

Mock-up of dissimilar metal weld

on a pressurising safety relief line

British Energy SRV Weld Mock-Ups

Mock-Up A w/o weld overlay
Mock-Up B w weld overlay

Modelling of Nuclear Dissimilar Weld

OVERLAY: 543 passes
Overlays
PIPE WELD: 15
passes

Alloy 316

Inconel
52

Alloy 508 Cl 3

Inconel
82/182
INSTRUMENTED MOCK
UP

BUTTERING: 94 passes

DISSIMILAR WELD: 46
passes

Full axi-symmetric model of instrumented mock up

contains 598 weld passes in four1different alloys

Fusion Boundary, Thermal

Model
Dissimilar Metal Weld (DMW)

nozzle
buttering

safeend
Accumulated fusion
boundary (1400C isotherm)
of 46 passes,
Inconel 82/182

20

DISSIMILAR WELD: Development of Residual

Stresses
S33, Hoop Residual Stresses

Residual Stress, Mechanical Model

Weld Overlay

Hoop stress

Residual Stress, Mechanical Model

Weld Overlay

Final comments
Simulations without verification are
hard to publish
Recently even simulations with
verification are hard to publish
We need to develop further

Damage mechanics .. (Verified??)