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Three dimensional multi-pass repair weld simulations

Elcoate, C. D.; Dennis, R. J.; Bouchard, P. J. and Smith, M. C. (2005). Three dimensional multi-pass repair weld simulations. International Journal of Pressure Vessels and Piping, 82(4) pp. 244–257.

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Full 3-dimensional (3-D) simulation of multi-pass weld repairs is now feasible and practical given the development of improved analysis tools and significantly greater computer power. This paper presents residual stress results from 3-D finite element (FE) analyses simulating a long (arc length of 62°) and a short (arc length of 20°) repair to a girth weld in a 19.6 mm thick, 432 mm outer diameter cylindrical test component. Sensitivity studies are used to illustrate the importance of weld bead inter-pass temperature assumptions and to show where model symmetry can be used to reduce the analysis size.

The predicted residual stress results are compared with measured axial, hoop and radial through-wall profiles in the heat affected zone of the test component repairs. A good overall agreement is achieved between neutron diffraction and deep hole drilling measurements and the prediction at the mid-length position of the short repair. These results demonstrate that a coarse 3-D FE model, using a ‘block-dumped’ weld bead deposition approach (rather than progressively depositing weld metal), can accurately capture the important components of a short repair weld residual stress field. However, comparisons of measured with predicted residual stress at mid-length and stop-end positions in the long repair are less satisfactory implying some shortcomings in the FE modelling approach that warrant further investigation.

Item Type: Journal Item
Copyright Holders: 2004 Elsevier Ltd
ISSN: 0308-0161
Keywords: weld modelling; residual stress; multi-pass; finite element
Academic Unit/School: Faculty of Science, Technology, Engineering and Mathematics (STEM) > Engineering and Innovation
Faculty of Science, Technology, Engineering and Mathematics (STEM)
Item ID: 15058
Depositing User: P. John Bouchard
Date Deposited: 17 Mar 2009 10:14
Last Modified: 09 Dec 2018 01:04
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