A Study on the Effects of Welding Deformation According to Weld Sequence in Overlay-Welded Structures

In this study, thermal elasto-plastic finite element analysis was conducted to derive the optimal welding sequence to minimize overlay welding deformation on the water wall panels of an SRF (solid refuse fuel) boiler. The water wall panels of an SRF boiler are exposed to high temperatures and corrosive environments, making overlay welding essential. However, because the length of the water wall panels and tubes exceeds 7 m, significant deformation occurs after overlay welding. Additionally, due to the large size of the water wall panels, full-size thermal elasto-plastic analysis requires huge computational costs. Therefore, in this study, the effects of welding sequence on overlay welding deformation were first investigated for a reduced model to derive the optimal welding sequence. Subsequently, an analysis model for the full-size pipe panels was established to compare and analyze the conventional welding sequence with the optimal welding sequence, thereby verifying the validity of the study. According to the welding sequence derived from the reduced model, welding deformation in the full-size model was significantly reduced compared to the conventional sequence. This reduction in deformation was discussed by analyzing the deformation behavior of the structure at each stage of the overlay welding process.