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Abstract
T-joint ®llet welds are extensively used in ship engineering and bridge structures. Localized heating from the welding process
and subsequent rapid cooling induce tensile residual stress near the toe of the T-joint in ®llet welds. Welding produces thermal
stresses that cause structural distortions, which in¯uence the buckling strength of the welded structures. This study describes the
thermal elasto-plastic analysis using ®nite element techniques to analyse the thermomechanical behaviour and evaluate the residual
stresses and angular distortions of the T-joint in ®llet welds. Furthermore, this work employs the technique of element birth and
death to simulate the weld ®ller variation with time in T-joint ®llet welds. Also discussed are the effects of ¯ange thickness,
welding penetration depth, and restraint condition of welding on the residual stresses and distortions. q 2001 Elsevier Science Ltd.
All rights reserved.
Keywords: T-joint ®llet weld; Residual stresses; Angular distortions
element `birth and death' to simulate the weld ®ller model. An element's strain is also set to zero as soon
variation with time in T-joint ®llet welds. All elements as that element is `killed'. Similarly, when elements are
must be created, including those weld ®llers to be born, they are not actually added to the model, but are
`born' in later stages of the analysis. The method simply reactivated. When an element is reactivated, its
proposed does not remove elements to achieve the stiffness, mass, element loads, etc. return to their full
`element death' effect. Instead, the method deactivates original values. Thermal strains are computed for newly
them by multiplying their stiffness by a severe reduction activated elements according to the current load step
factor. Although zeroed out of the load vector, element temperature.
loads associated with deactivated elements still appear
in element-load lists. Similarly, mass, damping, speci®c
heat, and other such effects are set to zero for deacti- 2.3. Veri®cation
vated elements. The mass and energy of deactivated
elements are excluded from the summations of the The proposed method was compared with ®nite
526 T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538
element and experimental results taken from Ma et al. the width of the ¯ange. The solid lines and broken
[13] and Shim et al. [14] to con®rm its accuracy. Ma et lines in Fig. 3 represent the residual stress computed
al.'s investigation computed the residual stress in T- by Ma et al. and this work, respectively. According to
joint ®llet welds using thermal elastic plastic three- Fig. 3, the residual stress distributions computed by the
dimensional FEM and generalized plane strain FEM. method proposed here show very good agreement with
Fig. 3 portrays the residual stress distributions across those determined by three-dimensional FEM.
Fig. 3. Residual stress computed by Ma et al.'s three-dimensional FEM and present method.
T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538 527
For Shim et al.'s investigation, a specimen was presented experimental results for the problem. Addi-
constructed using multi-pass butt welding, with a length, tionally, the ABAQUS ®nite element package is applied
width and thickness of L 1000 mm; W 400 mm; t as a comparison. As Fig. 5 indicate, the ABAQUS
25:4 mm; respectively, as shown in Fig. 4. The welding package result showed slightly lower tensile transverse
used the submerged arc technique. Pass sequences and stress near the weld centreline. The present method
welding parameters are shown in Table 1. Figs. 5 and 6 tends to the experimental results near the surface. As
portray the distribution of the transverse and longitudi- Fig. 6 indicate, both analysis results show tensile stress
nal >residual stress on the thick plate computed by near the weld centreline.
Shim et al. and the present method. Shim et al. [14] The residual stress calculated using the present method
Table 1
Schematics of pass sequences along with welding parameters for each pass
Pass no. (1±11) Voltage (V) Current (A) Speed (mm sec 21)
1 25 190 3.34
2±5 26 215 4.70
6 25 190 3.37
7±9 26 220 4.70
10±11 27 250 4.70
528 T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538
correlates well with that determined using Ma et al.'s of the webs are assumed to be simultaneously welded
three-dimensional FEM and that found in Shim et al.'s under the same welding conditions. Therefore, the
experiments. Therefore, the procedure proposed here is T-joint ®llet weld can be considered to be symmetrical
considered appropriate for analysing residual stresses and with the Y±Z plane. his work develops a two-
distortions due to welding. dimensional symmetrical generalized plane strain model
to calculate the residual stresses of the T-joint ®llet
weld using the ®nite element method. With the aid
3. Analysis of T-joint ®llet weld of this generalized plane strain condition, the three-
dimensional residual stress components distributed in
3.1. Specimen and material properties the transverse section can be computed by thermal
elasto-plastic analysis using ®nite element tech-
Fig. 7 depicts two plate ®llet weld. The length of the
niques with unit thickness. The model employs two-
®llet weld, the width of the ¯ange and height of the
dimensional four node plane elements, including the
web are assumed to be 500, 200 and 100 mm, respec-
®nite element meshes for the ®llet weld, along with
tively. The plate thickness is 16 mm for the ¯ange and
re®ned meshes used in the weld area. The symmetric
12 mm for the web. The plate material is SAE 1020,
model has 439 elements and 514 nodes as shown in
and the mechanical properties are dependent on the
Fig. 9.
temperature history, as Fig. 8 illustrates.
3.4. Mesh sensitivity study
3.2. Welding conditions
To examine the adequacy of element sizes, the effect
The welding parameters chosen for this analysis of mesh re®nement in the weld area was studied. A new
were as follows: welding method, single pass gas model with re®ned meshes consists of 507 elements
tungsten-arc welding; welding current, I 260 A; and 585 nodes. Results from two mesh densities with
welding voltage, V 20 V; and welding speed, the same material model and geometry showed little
v 5 mm sec21 . For practical welds, the heat sources difference. Therefore, the original FEM model with-
are applied along the weld path. However, this investi- out mesh re®nement in the weld joint is used for this
gation simulates the increment of heat loading on the study.
welding process via the lead temperature curve as
shown in Fig. 2. 3.5. Analysis procedure
3.3. Finite element model for T-joint ®llet welds During each weld pass, thermal stresses are cal-
culated from the temperature distributions deter-
In the T-joint ®llet weld, the welds on both sides mined by the thermal model. The residual stresses
530 T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538
from each temperature increment are added to the plates near the ®llet weld toes. The value of the residual
nodal point location to determine the updated beha- stress near the weld toes is 25 MPa and decreases to
viour of the model before the next temperature zero as the distance from the weld toes increases.
increment. Owing to the locally concentrated heat source, the
temperature near the weld bead and heat-affected zone
rapidly changes with distance from the heat source, i.e.
the highest temperature is limited to the domain of the
heat source, from which lower temperature zones fan
4. Results and discussion out. According to Fig. 10 the temperature non-
uniformity varies the shrinkage through the weldment
4.1. Transverse residual stresses thickness during cool-down and, consequently a high
tensile residual stress occurs on the surface of the
A stress acting normal to the direction of the weld weld toes.
bead is known as a transverse residual stress, denoted
s x . Fig. 10 represents the distributions of the residual 4.2. Longitudinal residual stresses
stress s x along the X direction. A very large tensile
residual stress is produced at the surface of the base A stress acting parallel to the direction of the
T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538 531
the changes of angular distortion (Du ) with cooling in the upper portion exceeds that in the lower one.
time. This ®gure reveals that the angular distortion Fig. 13 reveals that, after 20 s of weldment cooling,
downward is about 0.006 rad when the weldment has the angular distortion upward is approximately
cooled for 2 s. This is because the thermal expansion 0.003 rad, and almost does not change. This is because
the upwards bend of the ¯ange due to plastic deforma-
tion in the upper portion exceeds that in the lower
portion.
Fig. 14. Transverse residual stress distributions for different ¯ange thickness.
534 T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538
Fig. 15. Longitudinal residual stress distributions for different ¯ange thickness.
Fig. 17. Transverse residual stress distribution for different penetration depths.
investigates the effect of restraint conditions and reveals that the angular distortion with restraint is
restraint position on angular distortions and residual smaller than when the ¯ange is unrestrained. When
stresses. the applied restraint position is ®xed at 39.8 mm, this
Fig. 20 presents the angular distortion of the computation provides a minimum angular distortion
¯ange with various restraint positions. The ®gure 0.002 rad.
Fig. 18. Longitudinal residual stress distribution for different penetration depths.
536 T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538
5. Conclusions
Fig. 20. The angular distortion of the ¯ange with various restraint positions.
T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538 537
Fig. 21. Transverse residual stress distribution with restraint and in the unrestrained condition.
Fig. 22. Longitudinal residual stress distribution with restraint and in the unrestrained condition.
538 T.-L. Teng et al. / International Journal of Pressure Vessels and Piping 78 (2001) 523±538
and angular distortion near the toe can be reduced [6] Sasayama T, Masubuchi K, Moriguchi S. Longitudinal deformation
after the restraint force is released. When the applied of long beam due to ®llet welding. Welding J 1955:581±2.
[7] Guyot F. A note on the shrinkage and distortion of welded joints.
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distortion caused by one-pass ®llet welding. Welding J 1954:945±56.
[9] Nagaraja NR, Estuar FR, Tall L. Residual stresses in welded shapes.
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