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<p>For Hastelloy X flame tube film cooling hole TIG welding, the ultra-thin-walled effect (wall thickness δ ≤ 1.0 mm) and high-density weld layout (spacing ≤ 3 mm) necessitate welding sequence optimization as the dominant technique to control post-weld residual deformation, overshadowing the influence of traditional heat input parameters. This study conducts a thermo-mechanical coupling finite element analysis based on dynamic thermal plasticity theory. Through bidirectional validation between experimental data and simulation results, an “interval-symmetric” welding strategy is proposed to effectively mitigate deformation in thin-walled components. The results demonstrate that, compared to conventional “cross-symmetric” welding sequences, (1) the optimized process reduces cylindrical deformation by 21.17%, (2) circularity distortion by 37.96%, (3) heat-affected zone (HAZ) overlap rate by 32%, (4) and peak residual stress by 24.7%. Additionally, the post-weld straightening workload is simplified by 40%, significantly enhancing welding and shape-correction efficiency for flame tube assemblies. This approach holds substantial practical value for improving the manufacturing quality of flame tube components.</p>

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FE-simulation based deformation control of TIG welding sequences for Hastelloy X ultra-thin-walled components

  • 期刊论文

  • 发表日期：

    2025年12月11日

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  • Huimin Hao,
  • Quan Wu,
  • Geng Tang,
  • Xiaochen Yang,
  • Bangrui Zhang

摘要

For Hastelloy X flame tube film cooling hole TIG welding, the ultra-thin-walled effect (wall thickness δ ≤ 1.0 mm) and high-density weld layout (spacing ≤ 3 mm) necessitate welding sequence optimization as the dominant technique to control post-weld residual deformation, overshadowing the influence of traditional heat input parameters. This study conducts a thermo-mechanical coupling finite element analysis based on dynamic thermal plasticity theory. Through bidirectional validation between experimental data and simulation results, an “interval-symmetric” welding strategy is proposed to effectively mitigate deformation in thin-walled components. The results demonstrate that, compared to conventional “cross-symmetric” welding sequences, (1) the optimized process reduces cylindrical deformation by 21.17%, (2) circularity distortion by 37.96%, (3) heat-affected zone (HAZ) overlap rate by 32%, (4) and peak residual stress by 24.7%. Additionally, the post-weld straightening workload is simplified by 40%, significantly enhancing welding and shape-correction efficiency for flame tube assemblies. This approach holds substantial practical value for improving the manufacturing quality of flame tube components.