Examining Stress Relaxation in a Dissimilar Metal Weld Subjected to Postweld Heat Treatment

Dissimilar metal welds are often required in nuclear power plants to join components made from austenitic steels to those from ferritic steels, particularly in fast breeder reactor plants, in order to join the intermediate heat exchanger to the steam generator. The process of welding alters the microstructure of the base materials and causes residual stresses to form, both because of the change in the microstructure and the differing thermal histories in various regions. Postweld heat treatment (PWHT) is required to relieve the residual stresses and achieve preferable microstructural gradients across the weld joint. Therefore, in order to arrive at the optimal PWHT process, it is necessary to investigate the effects of heat treatment on the joint integrity, microstructure, and residual stress relaxation in the welds. To investigate the effect of PWHT on the residual stress relaxation and corresponding alteration of microstructure across a welded joint, a dissimilar weld between modified 9Cr-1Mo steel and austenitic stainless steel AISI 316LN was made using autogenous electron beam welding. To achieve this, the welding process was first modeled numerically using finite element analysis, and the residual stress predictions were validated by experimental investigation using neutron diffraction. The validated model was then used to study the residual stress relaxation through the simulation of PWHT. The predicted stress relaxation was compared with contour method measurement of residual stresses in the actual welded plate subjected to PWHT. The results indicate that, although some relaxation of residual stresses occurred during PWHT, there is still a significant portion of highly localized residual stresses left in the specimen

Control of welding residual stress for dissimilar laser welded materials

The most common problem of welding dissimilar metals (DMWs) with respect to residual stresses is the differences in the coefficient of thermal expansion and heat conductivity of the two welded metals. In the present work, a CO2 continuous laser welding process was successfully applied and optimized for joining a dissimilar AISI 316 stainless steel and low carbon steel plates. The Taguchi approach with three factors (selected welding parameters) at five levels each (L3-25) was applied to find out the optimum levels of welding speed, laser power and focal position for CO2 keyhole laser welding of dissimilar butt weld. The responses outputs were the residual stresses at different depth in the heat affected zone (HAZ). The Hole-Drilling Method technique was applied to measure the residual stress of dissimilar welded components. The results were analysed using analysis of variances (ANOVA) and signal-to-noise ratios (S/N) for an effective parameters combination. Statistical models were developed to describe the influence of the input parameters on the residual stress at different specimen levels; to predict there value within the limits of the variables under investigation. The result indicates that the developed models can predict the responses satisfactorily

Residual stress redistribution during elastic shake down in welded plates

Residual stresses are a consequence of welding in various structures such as ships and offshore structures. Residual stresses can be relaxed or redistributed according to the load levels during operation. The elastic shakedown phenomenon can be considered as one of the reasons for this change. This paper studies the relaxation/redistribution of weld residual stress during different levels of shakedown in a butt-welded plate chosen according to ship design and welding procedures. Welding was performed on DH36, a ship structural steel. Neutron diffraction was used to measure residual stresses in these plates in the as-welded state and after different levels of shakedown. A mixed hardening model in line with the Chaboche model is determined for both weld and base material. A numerical model is developed to estimate the shakedown limit on butt-welded plate. Further, the redistribution of residual stress in a numerical weld model according to the different levels of shakedown limit is studied. Based on the shakedown limit of the butt-welded plate, a shakedown region is determined, where the structure will undergo elastic shakedown in the presence of an existing residual stress field if the maximum stress on the load section after a few initial cycles is in the shakedown region

Pulsed eddy current applied to measure residual stress in welding

Welding is a manufacturing process of joining components that is dominant in industries that include civil, oil and gas, automotive, etc. Although it has various benefits, welding still causes residual stresses to remain in a component after welding. Residual stresses may result in unexpected failure and may worsen mechanical performance. Common methods to measure residual stresses include hole-drilling and X-ray diffraction and are characterized by their lack of reliability and complicated implementation process. In this study, pulsed eddy current (PEC) is introduced as a promising technique to measure subsurface residual stress in welding. First, the PEC method is calibrated and the correlation between signals and known stresses are identified, and then the residual stress in a welded component is estimated, and finally, the residual stresses measured by PEC were compared to the results obtained by the finite element technique

Effect of prior cold work on the mechanical properties of weldments

Heat exchanger units used in steam raising power plant are often manufactured using many metres of austenitic stainless steel tubes that have been plastically formed (bent and swaged) and welded into complex shapes. The amount of plastic deformation (pre-straining) before welding varies greatly. This has a significant effect on the mechanical properties of the welded tubes and on the final residual stress state after welding. The aim of the present work was to measure and understand the combined effects of pre-straining and welding on the properties and residual stress levels in stainless steel tubing weldments. Effects of plastic deformation were simulated by plastically straining three identical stainless steel tubes to different strain levels (0%, 10% and 20%). Then each tube was cut into two halves and welding back together. The variation in mechanical properties across weldments was measured using digital image correlation (DIC) and a series of strain gauges (SG). Residual stresses were measured on the 0% (undeformed) and 20% prestrained and welded tubes by neutron diffraction. It was found that the welding process had a marked effect on the tensile properties of parent material within 25mm of the weld centre-line. Evidence of cyclic strain hardening was observed in the tube that had not been pre-strained, and evidence of softening seen in the 10% and 20% pre-strained tubes. Macroscopic residual stresses were measured to be near zero at distances greater than 25 mm from the weld centre-line, but measurements in the 20% pre-strained tube revealed the presence of micro residual stresses having a magnitude of up to 50 MPa

The effect of vibratory stress on the welding microstructure and residual stress distribution

Previous studies have suggested that weld microstructure may be modified by the presence of static stresses. In this investigation, vibratory stress was applied to mild steel specimens while they were being welded to observe its effect on the residual stress, microstructure and hardness of the material. Residual stresses were found to decrease in response to vibration whether it was applied during welding or after welding. It was found that the applied stress influenced the grain growth process in the weld. As a result of the treatment the hardness of the material was found to be increased by 25 per cent

Residual stress measurement round robin on an electron beam welded joint between austenitic stainless steel 316L(N) and ferritic steel P91

This paper is a research output of DMW-Creep project which is part of a national UK programme through the RCUK Energy programme and India's Department of Atomic Energy. The research is focussed on understanding the characteristics of welded joints between austenitic stainless steel and ferritic steel that are widely used in many nuclear power generating plants and petrochemical industries as well as conventional coal and gas-fired power systems. The members of the DMW-Creep project have under- taken parallel round robin activities measuring the residual stresses generated by a dissimilar metal weld (DMW) between AISI 316L(N) austenitic stainless steel and P91 ferritic-martensitic steel. Electron beam (EB) welding was employed to produce a single bead weld on a plate specimen and an additional smoothing pass (known cosmetic pass) was then introduced using a defocused beam. The welding re- sidual stresses have been measured by five experimental methods including (I) neutron diffraction (ND), (II) X-Ray diffraction (XRD), (III) contour method (CM), (IV) incremental deep hole drilling (iDHD) and (V) incremental centre hole drilling (iCHD). The round robin measurements of weld residual stresses are compared in order to characterise surface and sub-surface residual stresses comprehensively

On the use of the Peak Stress Method for the calculation of Residual Notch Stress Intensity Factors: a preliminary investigation

Residual stresses induced by welding processes significantly affect the engineering properties of structural components. If the toe region of a butt-welded joint is modeled as a sharp V-notch, the distribution of the residual stresses in that zone is asymptotic with a singularity degree which follows either the linear-elastic or the elastic-plastic solution, depending on aspects such as clamping conditions, welding parameters, material and dimension of plates. The intensity of the local residual stress fields is quantified by the Residual Notch Stress Intensity Factors (R-NSIFs), which can be used in principle to include the residual stress effect in the fatigue assessment of welded joints. Due to the need of extremely refined meshes and to the high computational resources required by non-linear transient analyses, the R-NSIFs have been calculated in literature only by means of 2D models. It is of interest to propose new coarse-mesh-based approaches which allow residual stresses to be calculated with less computational effort. This work is aimed to investigate the level of accuracy of the Peak Stress Method in the R-NSIFs evaluation

Acceptability of Residual Stresses Measurement Methods of Butt Weldments and Repairs

The joints made by fusion of materials are exposed to the influence of residual stresses induced by welding thermal cycles. Residual stresses were measured on butt welded plates made of NIOMOL 490K, before and after reparation. The objective of this paper is to compare three methods of residual stress measurement (hole-drilling method, x-ray diffraction and directional effective permeability) induced by two welding processes (Submerge Arc Welding and Transferred Ionized Molten Energy) of V-butt welded plates. The residual stresses values are higher after reparation than before reparation of welded joints

The effect of residual stresses on the strain evolution during welding of thin-walled tubes

In many applications, negative effects of residual stresses in the material stemming from the production process, are regularly encountered. These residual stresses in cold-rolled steel tubes are mainly due to two mechanisms: (i) the rolling of the flat plate into a circular cross-section and (ii) afterwards closing this section with a weld bead. This research focuses on the residual stresses due to the welding process. In an experimental setup abstraction is made of the real production process of the tube. A finite element model is built of this experimental setup. Validation of the welding simulations is done by comparing the strain evolution in both the experiment and the simulation. In this validation process, sometimes a discrepancy between the measured strain evolution and the one obtained from the numerical analysis is seen. In this contribution it is numerically investigated how initial residual stresses affect the thermal strain evolution in the tube during the welding process. This is done in two ways: firstly an initial stress field in hoop direction, based on the spring back of the tube when cut is taken as the reference state and secondly the stress/strain state after the first weld is used in stead of the virgin material state. The conclusion for both assumptions is that the strain evolution during the welding is affected by the initial stress/strain state of the material