Residual Stresses and Distortion

Residual Stresses and Distortion

Lesson Objectives
When you finish this lesson you will
understand:
the generation of residual stress and
distortion in welds
mechanisms to reduce residual stress

Learning Activities
1. Read Handbook
pp 218-229
2. View Slides;
3. Read Notes,
4. Listen to lecture
5. Do on-line
workbook

Keywords
Thermal Expansion Coefficient, Residual Stress, Distortion,
Stress-Relief

Welding Design
Welding design involves consideration
of strength requirements, cost, and
service conditions
Mechanical & Physical properties
Joint Design
Welding stress and distortion

Covered
Earlier

0.1.1.3.0.T1.95.12

Residual Stress and Distortion

Residual Stress & Distortion in Welds

Heat flows from the weld area and causing
the joint area to expand (See Previous Module)
Thermal expansion and contraction due to
welding can leave behind permanent stress
and distortion
Higher heat input welds are more prone to
residual stress and distortion
Increased restraint can decrease distortion
but can result in higher residual stress
0.1.1.3.3.T18.95.12

Residual Stress and Distortion

Residual Stress Pattern

Tension

Compression

Residual stress is
present across an
unrestrained butt weld
after cooling
Tension near weld bead
Compression away
from the weld bead
Restraint can affect this
stress state

Turn to the person sitting next to you and discuss (1 min.):

We have seen from the metallurgy module that dislocation
tangles and pile-ups occurring above the yield strength of
materials cause the higher stresses. We have seen here that
by a temperature cycle that varies across the plate we have
regions that yield and residual stresses occur. We have seen
that imposing operating stresses above yield cause changes
in the residual stress distribution by movement of the
dislocations. How else then might we get rid of some of
these dislocations to remove these residual stresses?

Residual Stress and Distortion

Types of Distortion

0.1.1.3.3.T19.95.12

Residual Stress and Distortion

Distortion

Transverse Shrinkage Longitudinal Shrinkage

Rotational Distortion

Longitudinal Bending

Angular Change

Buckling

Residual Stress and Distortion

Eliminating Distortion

Angular distortion after welding

Preset members to
counteract distortion
Fixtures to clamp
workpiece in place
Restraint reduces
distortion but increases
residual stress

Preset members before welding

Stress-relief heat
treatment