MATHEMATICAL MODELLING OF WELD PHENOMENA 7 Edited by

H. Cerjak Institute for Materials Science, Welding and Forming Graz University of Technology

H. K. D. H. Bhadeshia Department of Materials Science and Metallurgy The University of Cambridge, UK

E. Kozeschnik Institute for Materials Science, Welding and Forming Graz University of Technology

TECHNISCHE UNIVERSITAT GRAZ

TUG

CONTENTS Introduction

xi

SESSION I: MELT POOL AND ARC PHENOMENA A Smart Bi-Directional Model of Heat Transfer and Free Surface Flow in Gas Metal Arc Fillet Welding for Practicing Engineers A. Kumar, W. Zhang, C.-H. Kim and T. DebRoy Effects of Latent Heat of Fusion on Thermal Processes during Welding V. A. Karkhin, H.-J. Pesch, A. S. Ilin, A. A. Prikhodovsky, V. V. Plochikhine, M. V. Makhutin and H.-W. Zoch Numerical Study of Transient Thermohydrodynamics of a Metallic Bath Heated by Electron Beam J.P. Bellot

3

39

63

Numerical Mig-Welding Simulation of Magnesium Alloys V. Michailov, M. Stadtaus, K. Dilger and M. Rethmeier

77

Modeling of Time-Dependent 3d Weld Pool Flow M. Do-Quang and G. Amberg

91

3D Numerical Model of Short-Circuiting Transfer Process in GMA Welding Y. Hirata, N. Ando, T. Osamura, M. Onda and T. Ohji

113

Visualization of Weld Pool Surface Flow During Tig Welding on Stainless Steel 316L Plates P. Henrikson

125

SESSION II: MICROSTRUCTURAL MODELLING IN WELD METAL AND HEAT AFFECTED ZONE Modelling of Laser Welded Joints and Microstructure - A Review & Outlook R. G. Thiessen and I. M. Richardson

151

vi

Mathematical Modelling of Weld Phenomena 7

Modelling and Characterization of Nonequilibrium Weld Microstructure Evolution 179 S. S. Babu, S. A. David, M. L. Santella, J. M. Vitek, E. D. Specht andJ. W. Elmer Novel Silicon-Rich Bainitic Steel Welds H. K. D. H. Bhadeshia, M. Lord and L.-E. Svensson Numerical Simulation on Transformation Process during Multi-Pass Tig Welding A. V. Tsarkov, G. P. Pantuhov, N.-E. Hannerz and P. Kihlmark Welding Of Single Crystal Nickel-Based Superalloys J. M. Vitek, S. S. Babu, J.-W. Park and S. A. David Microstructure Anticipation in the Heat Affected Zone of Gma Steel Welds by the Numerical Model Z. Odanovic and L. J. Nedeljkovic Numerical Simulation of Thermomechanical Phenomena during Tig Welding and Experimental Validation on Analytical Tests of Increasing Complexity L. Depradeux and J. -F. Jullien Some Remarks on the Influence of the Constraint Effect on the Relation between Microstructure and Mechanical Properties of Heterogeneous Welded Joints E. Ranatowski

207

219

235

251

269

295

Laser Weld Induced Microstructural Changes in Automotive Bodysheet N. J. Den Uijl and M. Anwar /

309

Modeling of HSLA-65 GMAW Welds E. A. Metzbower, D. W. Moon, C. R. Feng, S. G. Lambrakos and R. J. Wong

327

SESSION III: MICROSTRUCTURE, MECHANICAL PROPERTIES AND COMPONENT BEHAVIOUR In-Situ Observations of Phase Transformations in the Fusion Zone of Ti6A1-4V Alloy Transient Welds using Synchrotron Radiation J. W. Elmer, T. A. Palmer, S. S. Babu, W. Zhang and T. Debroy

343

Contents vii

Development of the Strains during Local Explosive Post Treatment of Welded Joints N. Doynov, S. Christov, V. Michailov and H. Wohlfahrt

363

The Importance of Modelling Elevated Temperature Material Response and Large Deformations in Resistance Upset Welds J. W. Foulklll, A. R. Ortega and D. J. Bammann

377

Numerical Analysis of Crack Growth Phenomena in the Airplane Structures A. Vichniakov, H.-J. Schmidt andB. Schmidt-Brandecker

391

Spotweld Performance under High Strain Rate Loading Conditions V. Robin, G. Bernauer, T. Akguen and T. Heubrandtner

419

Numerical Simulation of Stress-Strain Relation and Ductile-To-Brittle Transition in Welded Joints Subjected to Different Strain Rate M. Mochizuki and M. Toyoda

435

Modelling of Thermal History in Electroslag Welds for Novel Building Constructions K. Ichikawa, Y. Hashiba, A. Nogami and Y. Fukuda

463

Trefftz Finite Element Formulation of a Spot Weld in Dynamic Crash Calculations T. Heubrandtner and T. Akgu'n

483

Fracture Analyses of Welded Components V. Robin, T. Pyttel, J. Christlein and A. Strafing

519

SESSION IV: SOLIDIFICATION CRACK PHENOMENA Prediction of Welding Hot Cracking using Temperature Dependent Interface Element - Modelling of Interfaces H. Murakawa, H. Serizawa and M. Shibahara Numerical Simulation and Prediction of Weld Solidification Cracking Y. Wei, Z Dong, R. Liu, Z. Dong and Y. Pan

539

555

viii

Mathematical Modelling of Weld Phenomena 7

Finite Element Simulation of Pear-Shaped Bead Cracking in Narrow Gap Welding using Temperature Dependent Interface Element M. Shibahara, H. Serizawa, H. Murakawa, T. Nakamura and K. Hiraoka

573

SESSION V: RESIDUAL STRESSES AND DISTORTION Accounting for Welding Residual Stresses in the Design Stage N. Enzinger

591

Prediction of Distortions of Large Thin Structures during Welding using Shell Elements and Multiscale Approaches F. Faure, J.-M. Bergheau, J.-B. LeblondandB. Souloumiac

605

A Method to Consider the Results of Previous Forming Processes in the Simulation of Laser Beam Welding M. F. Za'h, F. Auer, S. Roeren

621

Numerical Simulation of Welding for Determining the Residual Stress Field Application to Monopass Fillet Welds and Friction Stir Welding M. Clerge, D. Lawrjaniec, A. Abisror, C. Decker, M. Kocak and J. Dos Santos

635

Effects of the Structural Restraint Intensity on the Stress Strain Build Up in Butt Joints T. Boellinghaus, T. Kannengiesser and M. Neuhaus

651

The Numerical Modelling of Residual Stresses and Strains at Arc Welding by the Modulated Current M. Nurguzhin, G. Danenova and T. Shigaev

671

Simulation and Validation of Tig-Welding and Post Weld Heat Treatment on an Inconel 718 Plate A. Lundba'ck, H. Alberg and P. Henrikson

683

Challenge to Active In-Process Control of Welding Distortion M. Mochizuki and M. Toyoda Fracture Mechanics Analysis of a 16" PWR Dissimilar Weld Metal Pipe Junction P. A. Gilles, M. Borrego-Puche and G. Martin

697

713

Contents ix

Distortion and Stress Assessment and Optimization of PTA Welded Tools and Cutting Blades using the F.E. Method U. Semmler, K. Alaluss andK.-J. Matthes

731

Finite Element Modelling of GTA Weld Surfacing Applied to Hot-Work Tooling D. Klobcar, J. TusekandB. Taljat

747

FE-Welding Simulation and Distortion Measurement during Welding Using Optical Object Grating Method M. Brand, M. Petz, R. Tutsch, H. Wohlfahrt and V. Michailov

763

SESSION VI: HYDROGEN Hydrogen Behaviour in Welded Joints and Evaluation of its Role for Cold Cracking Part One: State of the Problem B. T. Alexandrov Hydrogen Behaviour in Welded Joints and Evaluation of its Role for Cold Cracking Part Two: Investigation Methodology B, T. Alexandrov

781

805

Numerical Simulations of Hydrogen Assisted Cracking in Girth Welds of Supermartensitic Stainless Steel Pipelines - Report II T. Boellinghaus, E. Viyanit and H. Hoffmeister

847

Numerical Simulation of the Tekken-Test for the Prediction of Cold Cracking Susceptibility , M. Stadtaus, H. Wohlfahrt, K. Dilger and V. Michailov

875

SESSION VII: SPECIAL WELDING PROCESSES Computer Simulation of Resistance Spot Welding Process A. De and L. Dorn Modelling of the Contact Condition at the Tool/Matrix Interface in Friction Stir Welding H. Schmidt, J. Hattel andJ. Wert

895

925

x

Mathematical Modelling of Weld Phenomena 7

Numerical Simulation of Flash Butt Welding of Railway Rails A. Skyttebol and L. B. Josefson

943

Development of Computer-Aided Optimization System for Transient Liquid Phase Bonding Process K. Saida, R. Sakamoto and K. Nishimoto

965

Influence of Electrical-Thermal Physical Properties in Resistance Spot Welding Modelling C. Srikunwong, T. Dupuy and Y. Bienvenu

999

SESSION VIII: MODELLING APPROACHES AND COMPUTER PROGRAMS Analysis of Welding and Heat Deposition Processes using an InverseProblem Approach S, G. Lambrakos and J. O. Milewski

1025

Software Package Simweld for Simulation of Gas-Metal-Arc-Welding Processes of Steels and Aluminium Alloys U. Dilthey, I. Dikshev, O. Mokrow and V. Pavlyk

1057

Fem Tool for Resistance Projection Welding A. Vichniakov and H. Herold

1081

Topical Issues in the Development of Expert Systems for Use in the Process Planning of Resistance Spot Welded Vehicle Structures /. Borhy and P. Szabo

1099

An Analytic-Numerical Assessment of the Thermal Cycle in HAZ with Three Dimensional Heat Source Models and Pulsed Power Welding E. Ranatowski and A. Pocwiardowski

1111

Author Index

1129