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<p>This research addresses the critical welding challenges of thick-walled asymmetric bevel T-joints in large-scale infrastructure components, exemplified by the cross-shaped box columns at Beijing Fengtai Station. Geometric asymmetry alters heat flow paths by constraining filler metal deposition and inducing asymmetric thermal gradients, which may lead to localized incomplete fusion defects and imbalanced residual stress distributions. Through integrated experimental measurements and ABAQUS numerical simulations, this study pioneers the quantification of asymmetric groove (40°/50°) effects on residual stress redistribution in thick-section T-joints. Key findings reveal that Sequence 1 outperforms other approaches, effectively reducing peak temperatures at the asymmetric bevel root, mitigating stress magnitude and redistribution, and achieving 18% distortion reduction. Welding direction significantly affects transverse stress peaks within the weld zone. Microstructural analysis demonstrates that Sequence 1 induces gradient HAZ structures—fine-grained zones exhibiting predominantly high-angle grain boundaries (avg. misorientation angle: 33.9°), while critical zones feature low-angle subgrain boundaries (avg. 18.9°). This sequence yields a weld zone hardness of 246 HV, significantly exceeding base metal values. A digital twin protocol integrating ABAQUS DFLUX and EBSD was developed, establishing an innovative methodology for certifying geometrically complex beveled joints. This framework provides critical theoretical and practical guidance for engineering applications.</p>

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Welding Sequence Optimization for Asymmetric K-Groove T-Joints in Thick Q345C Steel Columns for Microstructure and Thermal and Mechanical Properties

  • 期刊论文

  • 发表日期：

    2025年10月6日

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  • Zhicheng Bi,
  • Hongchao Ji,
  • Xiaoli Yu,
  • Shanshan Wang,
  • Zhenhong Duan,
  • Xiaoming Yang

摘要

This research addresses the critical welding challenges of thick-walled asymmetric bevel T-joints in large-scale infrastructure components, exemplified by the cross-shaped box columns at Beijing Fengtai Station. Geometric asymmetry alters heat flow paths by constraining filler metal deposition and inducing asymmetric thermal gradients, which may lead to localized incomplete fusion defects and imbalanced residual stress distributions. Through integrated experimental measurements and ABAQUS numerical simulations, this study pioneers the quantification of asymmetric groove (40°/50°) effects on residual stress redistribution in thick-section T-joints. Key findings reveal that Sequence 1 outperforms other approaches, effectively reducing peak temperatures at the asymmetric bevel root, mitigating stress magnitude and redistribution, and achieving 18% distortion reduction. Welding direction significantly affects transverse stress peaks within the weld zone. Microstructural analysis demonstrates that Sequence 1 induces gradient HAZ structures—fine-grained zones exhibiting predominantly high-angle grain boundaries (avg. misorientation angle: 33.9°), while critical zones feature low-angle subgrain boundaries (avg. 18.9°). This sequence yields a weld zone hardness of 246 HV, significantly exceeding base metal values. A digital twin protocol integrating ABAQUS DFLUX and EBSD was developed, establishing an innovative methodology for certifying geometrically complex beveled joints. This framework provides critical theoretical and practical guidance for engineering applications.