Residual stress field and distortions resulting from welding processes: numerical modelling using Sysweld

This paper concerns the study of residual stresses and distortions in fusion butt joint welding, using the computational modelling software ESI Sysweld. Thermal gradients across the part will introduce geometrical variations that cause residual stress and distortions; their study and prediction are critical to ensure a sound welding.

To foresee the welding behaviour is a complex task because there are many physical-chemical phenomena involved in the welding processes. Using Sysweld - a finite element method based software - it is possible to integrate all the physical-chemical phenomena and elaborate computational models for most welding cases.

A real case consisting of three sets of aluminium plates welded by laser will be studied in this paper. A finite element model is realized for each case and the results are analysed using Sysweld capabilities.