Scholarlink

<p>Hindrance to expansion and shrinkage in dissimilar welded joints due to continuous non-uniform cycles of heating, cooling, and solidification during the weld torch movement introduces inevitable residual stress and distortion in welded structures. However, an appropriate choice of groove design (narrow gap) and welding process can significantly mitigate residual stress and distortion. Therefore, multi-pass pulsed gas metal arc welding (GMAW-Pulse) was used to join T/P92 and AISI304L steels with both conventional and narrow gap groove designs, employing ER308L and superalloy ERNiCrMo-3 (IN625) filler wires. Residual stress analysis for each case was performed using synchrotron X-ray diffraction and compared with finite element method (FEM) predictions, where the element birth and death technique was applied to simulate filler metal deposition. Both FEM and experimental measurements revealed that a narrow gap weld with ERNiCrMo-3 filler exhibited a much narrower distribution of tensile and compressive residual stresses due to uniform heat distribution across the weld. Percentage errors at tensile stress peaks ranged from 3.62 to 6.75% (in all four cases), with an average of 4.85%, confirming overall consistency between S-XRD and FEM results. These findings from finite element simulations are in reasonable agreement with experimental outcomes. This work may offer a valuable reference for design engineers and researchers seeking to improve weld quality and structural integrity through advanced experimental and simulation techniques for improving the design, maintenance, and safety protocols of pipeline systems in power generation facilities.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Residual stress mitigation in dissimilar T/P92 and AISI304L steel multi-pass weld joint using ER308L and ERNiCrMo-3 (IN625) fillers: simulation and experimental approach

  • 期刊论文

  • 发表日期：

    2025年10月16日

查看全文
  • Pavan Meena,
  • Ramkishor Anant

摘要

Hindrance to expansion and shrinkage in dissimilar welded joints due to continuous non-uniform cycles of heating, cooling, and solidification during the weld torch movement introduces inevitable residual stress and distortion in welded structures. However, an appropriate choice of groove design (narrow gap) and welding process can significantly mitigate residual stress and distortion. Therefore, multi-pass pulsed gas metal arc welding (GMAW-Pulse) was used to join T/P92 and AISI304L steels with both conventional and narrow gap groove designs, employing ER308L and superalloy ERNiCrMo-3 (IN625) filler wires. Residual stress analysis for each case was performed using synchrotron X-ray diffraction and compared with finite element method (FEM) predictions, where the element birth and death technique was applied to simulate filler metal deposition. Both FEM and experimental measurements revealed that a narrow gap weld with ERNiCrMo-3 filler exhibited a much narrower distribution of tensile and compressive residual stresses due to uniform heat distribution across the weld. Percentage errors at tensile stress peaks ranged from 3.62 to 6.75% (in all four cases), with an average of 4.85%, confirming overall consistency between S-XRD and FEM results. These findings from finite element simulations are in reasonable agreement with experimental outcomes. This work may offer a valuable reference for design engineers and researchers seeking to improve weld quality and structural integrity through advanced experimental and simulation techniques for improving the design, maintenance, and safety protocols of pipeline systems in power generation facilities.