Prediction of welding sequence induced thermal history and residual stresses and their effect on welding distortion

Stiffened plate panel is the major structural part of a fabrication industry where fillet welding joint is one of the most important fabrication techniques. Large stiffened structures are generally joined by several welding passes which generates thermal stresses and angular deformation. Tensile residual stresses which are generated due to welding in the weld region may lead to early failure of the structure when subjected to cyclic loading. The weld-induced residual distortion causes dimensional inaccuracy and needs rework to achieve the desired shape. Use of multiple welding passes without any optimized welding sequences typically leads to an increased degree of nonuniform heating and cooling, i.e., creating complex welding residual stress and angular deformation in the structure. In this present study, the effect of four different welding sequences on submerged arc welded fillet joint has been studied. A finite element-based numerical model has been developed to predict the thermal profile, welding residual stress, and angular deformation. The developed model considers temperature-dependent material property and material deposition by using element death and birth technique. The results have been compared with experimental one. In the effect of welding sequence on residual stress, angular deformation has been studied. Thus, the developed model presents the effect of welding sequence on the weld induced residual stresses and distortions which provide one of the most optimal welding sequence for enhanced fabrication process.