Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding
Welding thick plates induces more complex residual stress distributions than thin plates, with traditional thermo-mechanical model struggling to accurately predict the impact of molten pool flow and weld bead morphology. This study proposes a novel thermal fluid mechanical model (CFD-FEM) by integra...
Saved in:
| Main Authors: | , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-05-01
|
| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425011445 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850143607120461824 |
|---|---|
| author | Yonghui Su Haitao Xia Shuo Chen Chen Wang Shuaiyu Wu Wei Lu Jun Zhu Hao Wu |
| author_facet | Yonghui Su Haitao Xia Shuo Chen Chen Wang Shuaiyu Wu Wei Lu Jun Zhu Hao Wu |
| author_sort | Yonghui Su |
| collection | DOAJ |
| description | Welding thick plates induces more complex residual stress distributions than thin plates, with traditional thermo-mechanical model struggling to accurately predict the impact of molten pool flow and weld bead morphology. This study proposes a novel thermal fluid mechanical model (CFD-FEM) by integrating the computational fluid dynamics (CFD) model and the finite element method (FEM) model, considering molten pool flow. The gas-metal interface is captured employing the Volume of Fluid (VOF) method, enabling accurate extraction of the solidified weld bead morphology for each pass in thick multi-pass welding. This morphology is then utilized in the FEM model to reconstruct weld geometry for residual stress prediction. For double-V thick-plate butt welds, the CFD-FEM model, validated by blind-hole tests, reduces Root Mean Square Error (RMSE) by 47.77 MPa and Mean Absolute Percentage Error (MAPE) by 27.22 % compared with traditional model. The results demonstrate that convex weld bead formation is primarily driven by fluid momentum, surface tension gradients, and the Marangoni effect. The alternating welding strategy effectively reduces surface residual stress. By incorporating the cladding effect and providing more realistic weld bead morphology, the CFD-FEM model predicts residual stress of 478.43 MPa at adjacent weld junctions, compared with 243.26 MPa for the traditional model, better capturing local stress concentrations at the weld interface. |
| format | Article |
| id | doaj-art-e36bfe23b2074e5ab40b02ed98e0f65d |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-e36bfe23b2074e5ab40b02ed98e0f65d2025-08-20T02:28:38ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01367557757110.1016/j.jmrt.2025.04.323Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate weldingYonghui Su0Haitao Xia1Shuo Chen2Chen Wang3Shuaiyu Wu4Wei Lu5Jun Zhu6Hao Wu7School of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai, 200092, China; Nantong Taisheng Blue Island Offshore Co., Ltd., Nantong, 226251, ChinaSchool of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai, 200092, ChinaSchool of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai, 200092, ChinaNantong Taisheng Blue Island Offshore Co., Ltd., Nantong, 226251, ChinaNantong Taisheng Blue Island Offshore Co., Ltd., Nantong, 226251, ChinaShanghai Key Lab. of D&A for Metal-Functional Materials, School of Materials Science & Engineering, Tongji University, Shanghai, 201804, ChinaNantong Taisheng Blue Island Offshore Co., Ltd., Nantong, 226251, China; Corresponding author.School of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai, 200092, China; Nantong Taisheng Blue Island Offshore Co., Ltd., Nantong, 226251, China; Corresponding author. School of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai, 200092, China.Welding thick plates induces more complex residual stress distributions than thin plates, with traditional thermo-mechanical model struggling to accurately predict the impact of molten pool flow and weld bead morphology. This study proposes a novel thermal fluid mechanical model (CFD-FEM) by integrating the computational fluid dynamics (CFD) model and the finite element method (FEM) model, considering molten pool flow. The gas-metal interface is captured employing the Volume of Fluid (VOF) method, enabling accurate extraction of the solidified weld bead morphology for each pass in thick multi-pass welding. This morphology is then utilized in the FEM model to reconstruct weld geometry for residual stress prediction. For double-V thick-plate butt welds, the CFD-FEM model, validated by blind-hole tests, reduces Root Mean Square Error (RMSE) by 47.77 MPa and Mean Absolute Percentage Error (MAPE) by 27.22 % compared with traditional model. The results demonstrate that convex weld bead formation is primarily driven by fluid momentum, surface tension gradients, and the Marangoni effect. The alternating welding strategy effectively reduces surface residual stress. By incorporating the cladding effect and providing more realistic weld bead morphology, the CFD-FEM model predicts residual stress of 478.43 MPa at adjacent weld junctions, compared with 243.26 MPa for the traditional model, better capturing local stress concentrations at the weld interface.http://www.sciencedirect.com/science/article/pii/S2238785425011445Thermal fluid mechanical modelMolten pool flow behaviorWelding residual stresses evolutionLocal stress concentration |
| spellingShingle | Yonghui Su Haitao Xia Shuo Chen Chen Wang Shuaiyu Wu Wei Lu Jun Zhu Hao Wu Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding Journal of Materials Research and Technology Thermal fluid mechanical model Molten pool flow behavior Welding residual stresses evolution Local stress concentration |
| title | Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding |
| title_full | Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding |
| title_fullStr | Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding |
| title_full_unstemmed | Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding |
| title_short | Thermo-mechanical-fluid coupled modeling for residual stress prediction in thick plate welding |
| title_sort | thermo mechanical fluid coupled modeling for residual stress prediction in thick plate welding |
| topic | Thermal fluid mechanical model Molten pool flow behavior Welding residual stresses evolution Local stress concentration |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425011445 |
| work_keys_str_mv | AT yonghuisu thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT haitaoxia thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT shuochen thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT chenwang thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT shuaiyuwu thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT weilu thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT junzhu thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding AT haowu thermomechanicalfluidcoupledmodelingforresidualstresspredictioninthickplatewelding |