Welding, Residual Stress, Distortion

Control Methods and Applications of

Weld Modeling

Frederick (Bud) Brust

Engineering Mechanics Corporation of Columbus (Emc2)
Columbus, Ohio

Badri Athreya
Caterpillar, Inc.
Peoria, Ill

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Weld Modeling Advantage

Cost/Time Savings, Produce Cheaper Better Quality Products, Paradigm Shift Fabrication Methods

Residual Stress Control:

Fatigue, Corrosion, Fracture Control
Life Improvement, Quality

Related
Distortion Control:
Costs Reduction, Advanced Weld
Fabrication Methods, Fixture Design

Related
Microstructure Control:
Performance, Hardness, MartensiteBanite-Ferrite-Pearlite

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Virtual Fabrication Technology Software

(VFTTM)
EMC2/Battelle

F. W. Brust (LEADER)

Practical Weld Simulation Tools

Developed by Caterpillar/Battelle

Z. Cao
(Thermal)
J. Oh (Constitutive Models))
N. Ghadiali (GUI)
T. Forte
J. Hong (General)
F Jakob
(Thermal)
V. Li
(Structural/Materials)
J. Saunders (Thermal)
X. Sun
(Thermal/Mechanical)
Y. Yang
(Experimental/Structural)
J. Zhang (Thermal/Structural)
J. C. Kennedy

Caterpillar
L. Chuzoy
(Consultant)
Y. Dong
(Thermal/Structural)
T. Jutla
(General)
A. Nanjundan
(Thermal/Structural)
C. Sieck
(Consultant)
I. Varol
(Experimental)
D. Blunier
(General)
H. Ludwig
(Experimental/Welding)
P. Crilly
X. L. Chen
Z. Yang
B. Athreya

NIST ATP: FASIP circa 1995 - begins

Fabrication of Advanced Structures Using Intelligent and Synergistic Materials Processing

o
o
o

This Program Was a Significant Effort

Extensive Validation (Mostly Distortion)
Continual Improvements

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VFTTM Welding Simulation Flow

KEY: Rapid Solution Procedure for huge structures
Weld mesh
generator
Solid Model

Weld Info
processor
FEM Mesh

CUBIT

CTSP
DFLUX

GUI

Thermal Model

FZ2
HAZ2
2
1

ABAQUS

BM

HAZ1

Structural Model
Stresses

Distortions

Post processor
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UMAT-WELD
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Methods for WRS and Distortion Control

1.
2.

3.

4.
5.
6.

Weld Sequencing
Weld Parameter Definition (torch speed,
groove geometry, weld size, heat input, etc.)
Weld Procedure (fusion, electron beam, laser,
friction stir, hybrid laser/MIG, .)
Fixture Design (constraints, tack welds, ..
Pre-camber (elastic)
Peening (LSP, classical, etc.) - local

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Methods for WRS and Distortion Control

Pre-bend (plastic)
8. Thermal Tensioning (strategic heat source
introduction)
9. Heat Sink Welding (strategic cooling source
introduction)
10. PWHT
11. Control of Weld Consumable (eg. design
phase transformation)
12. Combinations of These
Weld Modeling Tools Can Help Evaluate New
Methods
7.

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Some Fabrication 3D Modeling Applications

Large MotorGrader
Drawbar

Large Hydraulic Excavator

Upper Frame

Ship Hull

Track-Type Tractor
Roller Frame

Large Hydraulic Excavator

Car body Ring

Articulated Truck
Case & frame

Wheel Loader
Boom

Track-Type Tractor
Case & frame
Barge Loader
Excavator
Moment Arm

Reactor
Frame

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Bi-Metallic
Nuclear Pipe

Ferritic
Stainless
Steel
Steel

Weld Design Optimization in A Large Structure

Cutting a section to study

the effect of weld design
B
A

1 pass bevel weld

3 pass T-fillet

D
7 pass V-groove

4
3 2
1

2
1

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3rdQrtReview.

10/7/20

A Section From the Large Complex Structure

3 pass T-fillet
(both straight side)

1 pass bevel weld

3 pass T-fillet
(both curve side)

4
3 2
1

Root pass,1,2,3,4,5,6,7

8 pass V-groove

4
3

2
1

Total Length of Welds: 26 m

A
D

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B
C
3rdQrtReview.

10/7/20

FE Model For This Section

7
5

6
4
3
2
1

8 pass V-groove
Number of Nodes: 16257
Number of Elements: 13288

4
2 3
1
3
1 2

Curve T-fillet
(1 pass bevel weld; 3 pass T-fillet)

Straight T-fillet (3 pass)

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3rdQrtReview.

10/7/20

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Distortion Comparison
20

Multi-pass Specimen

Displacement (mm)

15

10

Laser #4
LS4_predicted

D
-5
0

2500

5000

7500

10000

12500

B
C

20
15000

Time (Sec.)

LS4

LS7

Displacement (mm)

15

10

5
Laser #7
LS7_predicted
0

-5
0

2500

5000

7500

10000

12500

15000

Time (Sec.)
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3rdQrtReview.

10/7/20

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Controlling Welding-induced Distortion by

Weld Design Optimization
7
5

20

4
3
2
1

Laser #3
Laser #4
Laser #7
Laser #8

15

LS4

LS8

LS3
LS7

Original
Design

10

-5

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2500

5000

7500
10000
Time (Sec.)

12500

7
5

New
Design

4
3
2
1

Displacement (mm)

15000
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10/7/20

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Concurrent Product and Process Development:

Motor Grader Drawbar
Caterpillar

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Caterpillar Drawbar (Pre-Camber)

Baseline
Case

Pre_cambering

3.0
4.0
4.0

2.0
2.0 2.0

3.0

3.0

Original Geometry

5.9 mm
8.24 mm
Deformed Geometry

Distorted Shape - Side View

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Distorted Shape - Side View

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Fixture - Version n
and Pre-cambering Scheme
New fixture design
locates drawbar facing up

-1.0
-1.0

2.0

0.0

-1.0

3.0
2.0

-1.0

2.0

Special attention placed

to clamp supports and robot
access
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4.0
3.0
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Final Distortion

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Distortion Control Cost Savings

Caterpillar Example

Savings realized on Drawbar Structure:

Annual usage 5,000/year

Material, labor and overhead savings/unit = $200/unit
$1MM in direct annual savings for component
$1MM in one-time cost savings through elimination of
large straightening press
Cost savings is realized on numerous different
Caterpillar products

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Welding Assembly Barge Loader

One Time Build

Concern:

Sub 1

Excessive distortions from sub

assembly cause fit-up problem
in the top level welding.

Sub 2
Simulation:

Predict distortion from subassembly

Sequence
Fixture
Tack weld
Weld size (heat input)

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Sub 1
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Phase Transformation Plasticity Effects using VFTTM

Bead on Plate Specimen Geometry

With permission of Rolls Royce:

PVP2010-25649 (Seattle): Pellereau et al,
Rolls-Royce plc 2010
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Stress Results: 3-Pass

Longitudinal
Stress

Transverse Stress

Normal Stress

Prediction

Neutron Diffraction
Measurement

Rolls-Royce plc 2010

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Stress Results: Effect of Phase Change

Without Phase Change

With Phase Change

Longitudinal Stress

Transverse Stress

Normal Stress
Prediction

Prediction

Rolls-Royce plc 2010

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Ship Building Examples

VFTTM

Large Hull Penetrations

and Tanks

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TWI and UK MOD: Proceedings of Canada Defense Conference (Halifax, NS, 2007)
Bagshaw and Mawalla (Using VFT)

194 welds
90 Vertical (Tee Fillet)
104 Horizontal (Tee Fillet and Butt)
10 m

Blue (4mm)
Yellow (6 mm)
Green (7 mm)
Red (8mm)

Moving Arc: Shell Elements

78 % Reduction in Average Displacements by:
Perform vertical welds last
Increase weld speed from 140 to 250 mm/min
Modify Stud and Clamp Location
Use temporary stiffeners near laser cut doorway

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23

Stress Corrosion Crack

Growth Modeling in Bimetal
PWR Nuclear Pipe

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Partial Repair 3D Solutions Needed

Repair Cross
Section
(26% Through
Thickness)

225Degree
Station

Y
X Z

180-Degree Station

25
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Y
Z

90Degree
Repair

135Degree
Station

135-degree
135-degree
Grind/Repair Grind/Repair
End Location Start Location

Summary Bimetallic
Welding

Axis-symmetric Residual Stress Field

da/dt = C(KI)p

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Summary

Weld Modeling Now Being Used in the Design Process:

Distortion Control, Life Improvement

Elimination of non-valued added re-work fabrication

costs
Life cycle cost reduction from improved corrosion, and
fatigue performance and damage reduction
enhancement
Weld Modeling and Measurements Both Critical Aspects

The Publications Below Summarize more.

Chen, X. L., Yang, Z, and Brust, F. W., , Modeling Distortion and Residual Stress During
Welding, Chapter 7 in Processes and Mechanisms of Welding Residual Stress and Distortion,
pp. 225 263, Woodhead Publishing, July 2005, ed. Z. Feng.
Brust, F. W., and Kim, D., Mitigating Welding Residual Stress and Distortion, Chapter 8 in
Processes and Mechanisms of Welding Residual Stress and Distortion, pp. 264 294, Woodhead
Publishing, July 2005, Z. Feng, Editor.

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History Effects Sometimes Need to Consider

Paint

Machining
Welding
Fixturing
& Tacking
Forming
Cutting
Cleaning

Materials

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Residual Stress Engineering

ASME Pressure Vessel Piping Conference

Baltimore, July 17-22 2011
Session: Welding Residual Stress and Distortion
Simulation and Measurement (40 papers in Seattle in
2010)

bbrust@emc-sq.com
david.rudland@nrc.gov

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Back-up

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1

Tee-Fillet Weld Pre-camber

Final Distortion
Without
Pre-cambering
5.843
7.456
-3.3
8.309

Pre-camber
Amount

-4.7
-4.6

Final Distortion
With
Pre-cambering
-0.136
-0.155
-0.489
Fig.
12 Tee-Fillet
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Solutions

Weld pre-camber for distortion control.

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Shop Floor Practice of Pre-Straining Technique

(a) Before Welding

Bent Plate

(b) After Welding Pipe to Plate, then Machining weld

Plate becomes flat

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3rdQrtReview.

10/7/20

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PWSCC Crack Growth Example Wolf Creek Surge

PipeFracCAE

TM

Code

Pipe with crack in Weld Developed

a/t = .15, /=60
Loads: Residual Stress, Temp, Pres,
Moment
PWSCC (or Fatigue)
da
= 1.4 10 11 (K I 9)1.16 (m / sec)
dt

ANALYSIS PROCEDURE:
1. ABAQUS Analysis Extract Stress Intensity
Factor (K)
2. Crack Growth for all crack tip points

Natural PWSCC Crack Growth

3. Automatic Re-Mesh
4. Automatic ABAQUS Model Produced
5. LBB Assessment Made

NRC Procedure (Leak Rate,

Fracture)
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