Thermal Analysis of Welding in T-Joint Plates Using Finite Element Analysis

International Journal of Research in Advanced Technology - IJORAT
Vol. 2, Issue 1, JANUARY 2016
THERMAL ANALYSIS OF WELDING IN

T-JOINT PLATES USING FINITE
ELEMENT ANALYSIS
Mr. K.KRISHNAMOORTHY 1, Mr.S.SHEIK SULAIMAN 2, Mr.R.KARTHIKEYAN.3
Assistant Professor/Mechanical Engineering, Francis Xavier Engineering College, Tirunelveli, India 1
ABSTRACT: Welding is highly reliable and efficient metal joining process. The thermal response of
materials to a welding heat source sometimes causes mechanical problems, e.g. residual stresses and
distortion and changes in mechanical properties due to changes in the microstructure. The finite element
method (FEM) is the most commonly used numerical technique, which provides accurate estimates of
thermal parameters for this analysis. Finite element analysis (FEA) is a tool used especially in determining
the thermal stresses and temperature distribution of the welded models, which are difficult to analyze by
hand calculations. The objective of the current work is to evaluate transient thermal analysis in arc welded TJoint 304L stainless steel plates. The object is modeled in 3D and analyzed using FEA with an element type of
SOLID70. Energy is input into the thermal model using moving circular area heat source. The results
obtained by thermal analysis are used to determine the temperature distribution and temperature histories.
Keywords: FEA analysis, Heat sources, Temperature distribution, Temperature histories.
(HAZ). Finite Element Analysis (FEA) as a reliable
I. INTRODUCTION
To produce high strength welded structures,
method for this analysis.
arc welding is an effective and economic joining
During welding processes, heat can be
method attracting world welding community. Due to
transmitted by conduction, convection and radiation.
non-uniform expansion and contraction of the weld
For welding processes where an electric arc is used as
metal and surrounding base metal by heating and
the welding heat source, heat conduction through the
cooling cycles during welding, thermal stresses
metal body is the major mode of heat transfer and
occurs in the weld and adjacent areas. During the
heat convection is less significant as for as the
heating phase, the strains produced always induce
temperature field in the welded body is concerned.
plastic deformation of the metal. The stresses
The heat flow in the welding process presents a very
resulting from these strains combine and react to
complex situation, which currently defies the detailed
produce internal forces that cause a variety of
analysis by analytical calculations. However, this
welding
are
problem can be simplified by considering conduction
sometimes considered the weakest part in the object
only (on the basis of the limited effect of radiation)
owing to the possible reduced creep strength of the
and treating the convection by making use of an arc
weld metal and surrounding heat affected zone
efficiency parameter.
distortions.
Welded
steel
joints
1
All Rights Reserved 2016 IJORAT

II. HEAT SOURCE

The
temperature
vs.
time
relationship of welded components and structure can
2T 2T 2T 1 T
(1)
2 2 2
y
z a t
x
be theoretically obtained by carrying out a heat-
Where
transfer analysis of a welding process. This involves

many complicated heat-flow phenomena including
material
a is thermal diffusivity of the body

(a
heat radiation, convection, heat conduction as well as

fluid flow of melting weld metal. This process would
conductivity,
require
material)
solving
many
constitutive
differential
k
,
c
where
k-
thermal
- density, c- specific heat of the
equations using finite element or finite different

methods that are time consuming despite the fact that
III.GAUSSIAN - DISTRIBUTED AREA
the computing power continuous to improve.
HEAT SOURCE
Therefore, from a practical point of view, analytical
The Gaussian-distributed heat source is a
solutions for the heat-transfer problem in welding are
simplified model for a local concentration of a
preferable despite their limitations. Their major
welding heat input when its density is assumed to
advantage is that they are given in the closed form
follow the Gaussian distribution. Normally, the
equation that could provide the temperature-time
temperature field in the vicinity of the heat source is
information for the welding thermal problems in a
particularly dependent on the heat-flow density of the
rabid and convenient way. In most welding processes
heat source. However, the temperature at the far field
performed on thick plates, the heat flow in three
is less sensitive to the heat flow density; therefore,
dimensional (3D). For cases of high power or fast
the
moving heat sources, the heat flow along the travel
temperature distribution if the heat source is replaced
direction of the heat source can be neglected, hence,
by a concentrated point source in the centre of its
the one-dimensional heat flow can be used to model
area. Hence, the Gaussian-distributed heat source can
this situation. The solution to the heat-conduction
be used to simulate the welding heat source to give a
equation is based on the concept of an instantaneous
better prediction of the temperature field near the
heat source that is widely used in heat-conduction
source center to overcome the weakness point and
analysis. The concept of instantaneous heat sources
line heat source, which would predict an infinitely
assumes that the heat is released instantaneously at
high temperature at the source location. The Gaussian
t 0 in an infinite medium of initial
heat source is used to simulate the welding arc,
T0 either across a plane for a uniaxial
welding flame, or welding beam where the heat
time
temperature
distributed
conduction, along a line for biaxial conduction is in a
source density
point for triaxial conduction. The general governing
is represented by
heat-conduction is as follows,
heat
source
gives
similar
at an arbitrary point
exp( kr 2 )
(2)
2

where
is the maximum value of the heat source
density; r is the distance from
to the centre of
the heat source
and k is the
the point or line heat source that give an unrealistic

infinite temperature.
Where,
q = heat flux (W/m2),
coefficient determining the concentration of the heat
k = distribution parameter (m-2),
source, also known as distribution parameter, which
r = radius of the circular heat source (m),
represents the width of the Gaussian distribution
= density of the material (kg/m3).
curve (higher value of
c = specific heat (kJ/kg K),
corresponds to a more
concentrated heat source).A schematic illustration of
T0= initial temperature of the plate (0C).
the Gaussian area heat source.
T= temperature distribution (0C),

v= welding speed (mm/sec),
a= thermal diffusivity (m2/sec),
t= time (sec),
x= Distance along in x-direction (mm),
y= Distance along in y-direction (mm).
IV.FINITE ELEMENT ANALYSIS

The finite element method (FEM) (its
practical application often known as finite element
analysis (FEA)) is a numerical technique for solving
problems of Engineering and Mathematical Physics.
In this method, a body or a structure in which the
Fig. (1) Gaussian distributed area heat source
Let us assume that Q is the total output of the heat
source.
The
heat
equilibrium
Q=
condition
(3)
analysis to be carried out is subdivided into smaller

elements of finite dimensions called finite elements.
Then the body is considered as an assemblage of
these elements connected at a finite number of joints
called Nodes or nodal points. The properties of each
Subsequently, the maximum density of the heat
type of finite element is obtained and assembled
source,
together and solved as whole to get solution. In this
depending on the heat output, Q, and
T-joint have two plates (Fig. 2) have dimensions,

distribution parameter k as
and equation
horizontal
plate
length=100mm,
width=50mm,
thickness=6mm and vertical square plate have same
becomes,
Qk
exp( kr 2 )
It is worth noting that when
thickness and size=50mm. The finite element

(4)
the heat density
meshing is shown in (Fig. 3). It have 8476 nodes and

6175 brick node elements.
, this means that this Gaussian-distributed

density heat source will predict a finite temperature at
the heat source centre, which is more realistic than
3

Fig. (3) Finite Element meshing of T-joint plates
Fig. (2) Finite Element model of T-joint plates
V.MATERIAL PROPERTIES
Temperature
(c)
Specific
Conductivity
heat
(W/m C)
Density
Yield
Thermal
Youngs
Poissons
stress
expansion
modulus
ratio
(Kg/m )
(J/Kg C)
(Mpa)
coefficient
(Mpa)
10 /c
0
462
14.6
7900
256
1.7
199
0.294
100
496
15.1
7880
218
1.74
193
0.295
200
512
16.1
7830
186
1.8
185
0.301
400
540
18
7750
155
1.91
167
0.318
600
577
20.8
7660
149
1.96
159
0.326
800
604
23,9
7560
91
2.02
151
0.333
1200
676
32.2
7370
25
2.07
60
0.339
1300
692
33.7
7320
21
2.11
20
0.342
1550
700
120
7300
10
2.16
10
0.388
Table1: Temperature dependent thermal, physical and mechanical properties of 304L austenitic stainless steel. [1].
VI.THERMAL ANALYSIS
A thermal analysis calculates the temperature
the following formula can be used
distribution and related thermal quantities in a system or

component. In this work transient thermal analysis was
used To calculate the heat input for arc welding procedures,
(5)
Where Q = heat input (W), V = voltage (V), I = current (A)
=26 V,
=210 A, = 60%
4

In this thermal analysis of T-joint have

totally 25 load steps were involved in the moving
area heat source. Totally 10 seconds was consumed
to complete the welding process. The nodal
temperature solutions were obtained from the thermal
analysis. In 3D analysis, during a time step, the
welding arc is allowed to stay at the element with
The moving continuous area heat source of

the welded plates traveled along both sides of the
vertical plate simultaneously and same direction.
Under all these conditions, the thermal analysis
carried out and the data obtained from analysis saved
to a file. The thermal analysis results are shown in
following figures from 4 - 13
constant heat flux and then moved to next element.
VII.RESULTS
Fig. (4) Temperature distribution at .3sec

Fig. (6) Temperature distribution at 8 sec
Fig. (5) Temperature distribution at 2 sec

Fig. (7)Temperature distribution at 10sec
5

Fig. (8) Temperature distribution after cooling at 100sec
Fig.(11)Temperature history at node 425
Fig. (9) Temperature history at node 386
Fig. (12) Temperature distribution after cooling at

400sec
Fig.(10)Temperature history at node 410
Fig. (13) Temperature history after cooling at node 4283
6

REFERENCES
VII CONCLUSION
The normal results of welded T-joint was

obtained from thermal analysis, Show us the
temperature distribution at the parts. It is so
difficult to obtain this distribution from the
experiments.
Finite element method is an efficient technique
in welding analysis. Differences in physical,
mechanical and chemical properties of base
metals cause non uniform temperature
distribution and heat transfer.
The obtained temperature distribution and
temperature history is used to find out the
residual stress produced in welding.
ACKNOWLEDGMENT
[1]
S.Nadimi., R.J.Khoushehmehr., B.Rohini and

A.Mostafapour, Investigation and Analysis of
Weld
Induced
Residual
Stresses
in
Two
Dissimilar Pipes by Finite Element Modelling.

Journal of Applied sciences 8 (6): 1014-1020,
2008.
[2]
ANSYS guide, ANSYS release 10.0
[3]
Z.Barsoum, Residual Stress Prediction and
Relaxation in Welded Tubular Joint.

[4]
Xiangyang Lu and Tasnim Hassan., Residual

Stresses in Butt and Socket Welded Joints.
I am using this opportunity to express my gratitude to

everyone who supported me throughout the project. I
am thankful for their aspiring guidance, invaluably
constructive criticism and friendy advice during the
project work. I am sincerely grateful to them for
sharing their truthful and illuminating views on a
number of issues related to the project.
Transactions, SMiRT 16, Washington DC,

August 2001.
[5]
J.J.Dike., A.R.Ortega., C.H.Cadden., Finite

Element Modeling and Validation of Residual
Stresses in 304L Girth Welds. 5th International
Conference on Trends in Welding Research, June
I would also like to thank to all the people who

provided me with the facilities being required and
conductive conditions for my project.
1-5, 1998, Pine Mountain, GA.

[6]
Naeem Ullah Dar., Ejaz M.Qureshi., and M.M.I

Hammouda.,
Analysis
of
Weld-induced
Residual Stresses and Distortions in Thin-walled

Cylinders. Journal of Mechanical Science and
Technology 2 (2009) 1118-1131.
[7]
N.T. Nguyen., Thermal Analysis of Welds.

ETRS Pvt Ltd, WIT press, Australia, 2004.
[8]
John.A.Goldak
Computational
and
Mehdi
Welding
Akhlaghi.,
Mechanics.
Publication by Springer.
7

Thermal Analysis of Welding in T-Joint Plates Using Finite Element Analysis

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International Journal of Research in Advanced Technology - IJORAT

Vol. 2, Issue 1, JANUARY 2016

THERMAL ANALYSIS OF WELDING IN

(HAZ). Finite Element Analysis (FEA) as a reliable

method for this analysis.

arc welding is an effective and economic joining

During welding processes, heat can be

method attracting world welding community. Due to

transmitted by conduction, convection and radiation.

non-uniform expansion and contraction of the weld

For welding processes where an electric arc is used as

metal and surrounding base metal by heating and

the welding heat source, heat conduction through the

cooling cycles during welding, thermal stresses

metal body is the major mode of heat transfer and

occurs in the weld and adjacent areas. During the

heat convection is less significant as for as the

heating phase, the strains produced always induce

temperature field in the welded body is concerned.

plastic deformation of the metal. The stresses

The heat flow in the welding process presents a very

resulting from these strains combine and react to

complex situation, which currently defies the detailed

produce internal forces that cause a variety of

analysis by analytical calculations. However, this

problem can be simplified by considering conduction

sometimes considered the weakest part in the object

only (on the basis of the limited effect of radiation)

owing to the possible reduced creep strength of the

and treating the convection by making use of an arc

weld metal and surrounding heat affected zone

International Journal of Research in Advanced Technology - IJORAT

II. HEAT SOURCE

relationship of welded components and structure can

be theoretically obtained by carrying out a heat-

transfer analysis of a welding process. This involves

a is thermal diffusivity of the body

heat radiation, convection, heat conduction as well as

- density, c- specific heat of the

equations using finite element or finite different

III.GAUSSIAN - DISTRIBUTED AREA

the computing power continuous to improve.

Therefore, from a practical point of view, analytical

The Gaussian-distributed heat source is a

solutions for the heat-transfer problem in welding are

simplified model for a local concentration of a

preferable despite their limitations. Their major

welding heat input when its density is assumed to

advantage is that they are given in the closed form

follow the Gaussian distribution. Normally, the

equation that could provide the temperature-time

temperature field in the vicinity of the heat source is

information for the welding thermal problems in a

particularly dependent on the heat-flow density of the

rabid and convenient way. In most welding processes

heat source. However, the temperature at the far field

performed on thick plates, the heat flow in three

is less sensitive to the heat flow density; therefore,

dimensional (3D). For cases of high power or fast

moving heat sources, the heat flow along the travel

temperature distribution if the heat source is replaced

direction of the heat source can be neglected, hence,

by a concentrated point source in the centre of its