Welding Distortions Analysis Considering the Hardening Model, Deposition Processes, and Dissimilar Mechanical Behavior of the Base and Filler Metal

Abstract

The work presented in this paper focuses on modeling the welding process to develop a numerical model able to perform a good prediction of welding distortions. The model is developed for a butt welded joint using S235 steel as the base metal and an electrode (AWS E6013) as the filler metal. To assess accuracy, numerical and experimental results are compared. The present work makes it possible to identify the main factors influencing the accuracy of the numerical model, which must be taken into account to obtain satisfactory results. To carry out this analysis, the effect of the mechanical properties of deposited metal and the effect of the deposition process were taken into account. The effect of the variation of the mechanical properties of the filler metal on the distortions is illustrated. The model was developed by using APDL language, and the birth and death technique is used to model the deposition process. Distortion results obtained by numerical models approach properly the experimental measurement. Further analysis of the numerical data reveals considerable fluctuation of the obtained results by modifying the models used to describe the plastic behavior and the work hardening process. Regarding this strong correlation, numerical modeling of the welding process needs a vigilant identification of the work hardening mode appropriate for the used materials.