Residual Stresses and Distortion

Residual Stresses and Distortion Learning Activities

1. Read Handbook
Lesson Objectives pp 218-229
When you finish this lesson you will 2. View Slides;
understand: 3. Read Notes,
• the generation of residual stress and 4. Listen to lecture
distortion in welds 5. Do on-line
• mechanisms to reduce residual stress workbook

Keywords
Thermal Expansion Coefficient, Residual Stress, Distortion,
Stress-Relief
 Welding Design
Welding design involves consideration
of strength requirements, cost, and
service conditions
– Mechanical & Physical properties Covered
Earlier
– Joint Design
– Welding stress and distortion

0.1.1.3.0.T1.95.12
  T
 Residual Stress and Distortion

Residual Stress & Distortion in Welds

• Heat flows from the weld area and causing
the joint area to expand (See Previous Module)
• Thermal expansion and contraction due to
welding can leave behind permanent stress
and distortion
• Higher heat input welds are more prone to
residual stress and distortion
• Increased restraint can decrease distortion
but can result in higher residual stress
0.1.1.3.3.T18.95.12
 Residual Stress and Distortion

Residual Stress Pattern

• Residual stress is
present across an
unrestrained butt weld
after cooling
Tension
• Tension near weld
bead
• Compression away
from the weld bead
Compression • Restraint can affect
this stress state
Turn to the person sitting next to you and discuss (1 min.):
• We have seen from the metallurgy module that dislocation
tangles and pile-ups occurring above the yield strength of
materials cause the higher stresses. We have seen here that
by a temperature cycle that varies across the plate we have
regions that yield and residual stresses occur. We have seen
that imposing operating stresses above yield cause changes
in the residual stress distribution by movement of the
dislocations. How else then might we get rid of some of
these dislocations to remove these residual stresses?
 Residual Stress and Distortion

Types of Distortion

0.1.1.3.3.T19.95.12
 Residual Stress and Distortion
Distortion

Transverse Shrinkage Longitudinal Shrinkage Angular Change

Rotational Distortion Longitudinal Bending Buckling


Eliminating Distortion
Angular distortion after welding
Preset members before welding
Residual Stress and Distortion
• Preset members to
counteract distortion
• Fixtures to clamp
workpiece in place
– Restraint reduces
distortion but increases
residual stress
• Stress-relief heat
treatment