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<p>Despite the increasing concern about residual stress effects in welded structures, significant uncertainties still exist regarding the stresses and measurement procedures. This study explored residual stress characteristics in TIG-welded 5083 aluminum sheets at various cutting speeds and welding parameters to enable the reliable quantification of the stresses and the review of the practices of the process. Using a coupled experimental–numerical approach, data from wire-cut specimens were collected via the contour method (CMM-based). At the same time, welding processes were simulated in Abaqus with a double-ellipsoid Goldak heat source, employing stress profiling and error quantification to examine thickness effects, cutting speed impacts, and voltage/current sensitivity. Key results indicate that increasing sheet thickness from 3 to 4&#xa0;mm produces a dramatic increase in peak tensile residual stress by 25–30%. Cutting speed impacts results significantly; lowering the cutting speed from 2.28 to 1.6&#xa0;mm/min has dramatically decreased the potential error associated with tensile stress measurements on specimens of 3&#xa0;mm thickness from 20.8 to 2.08%. Thicker sheets of aluminum do exhibit increased residual stress levels; however, they show greater alignment of the numerical results with the experimental results, indicating a more even distribution of heating action and hence more uniform residual stress patterns even when subjected to larger baseline residual stress levels. Additionally, welding parameters exert a direct effect on the resulting level of residual stress. Increased voltage and current settings will directly increase residual stress levels; a 10% increase in voltage results in 12–18% higher peak tensile stress levels. The results of the current study not only confirm the accuracy of the finite element model as applied to the contour method, but they also reinforce the importance of optimizing welding parameters to minimize heat input when measuring, using proper specimen thickness and cutting speed to obtain accurate measurements of residual stress, designing reliable welded aluminum structures.</p>

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Residual stress in tungsten inert gas welded aluminum: a numerical and contour method correlation study on thickness and cutting speed effects

  • 期刊论文

  • 发表日期：

    2026年5月16日

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  • Hamid Abedi,
  • Reza Ahmadi Malek Abad,
  • Abbas Rahi

摘要

Despite the increasing concern about residual stress effects in welded structures, significant uncertainties still exist regarding the stresses and measurement procedures. This study explored residual stress characteristics in TIG-welded 5083 aluminum sheets at various cutting speeds and welding parameters to enable the reliable quantification of the stresses and the review of the practices of the process. Using a coupled experimental–numerical approach, data from wire-cut specimens were collected via the contour method (CMM-based). At the same time, welding processes were simulated in Abaqus with a double-ellipsoid Goldak heat source, employing stress profiling and error quantification to examine thickness effects, cutting speed impacts, and voltage/current sensitivity. Key results indicate that increasing sheet thickness from 3 to 4 mm produces a dramatic increase in peak tensile residual stress by 25–30%. Cutting speed impacts results significantly; lowering the cutting speed from 2.28 to 1.6 mm/min has dramatically decreased the potential error associated with tensile stress measurements on specimens of 3 mm thickness from 20.8 to 2.08%. Thicker sheets of aluminum do exhibit increased residual stress levels; however, they show greater alignment of the numerical results with the experimental results, indicating a more even distribution of heating action and hence more uniform residual stress patterns even when subjected to larger baseline residual stress levels. Additionally, welding parameters exert a direct effect on the resulting level of residual stress. Increased voltage and current settings will directly increase residual stress levels; a 10% increase in voltage results in 12–18% higher peak tensile stress levels. The results of the current study not only confirm the accuracy of the finite element model as applied to the contour method, but they also reinforce the importance of optimizing welding parameters to minimize heat input when measuring, using proper specimen thickness and cutting speed to obtain accurate measurements of residual stress, designing reliable welded aluminum structures.