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Using heat sink technology to decrease residual stress in 316L stainless steel
welding joint: Finite element simulation
Wenchun Jiang a, b, *, Yucai Zhang a, Wanchuck Woo b
a
b
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 24 August 2011
Received in revised form
23 December 2011
Accepted 3 January 2012
316L type stainless steel is widely used in chemical industries due to its excellent resistance to corrosion.
But the welding residual stresses have a great effect on stress corrosion cracking. This paper used nite
element method to study the effect of heat sink on residual stress. The effects of contact length and the
average heat transfer coefcient on residual stress have been investigated. It is found that the heat sink
technology can decrease the residual stress greatly. Compared to the model without heat sink, 20% of the
peak longitudinal stress has been reduced. The heat sink decreases the dwell time during cooling from
850 C to 400 C, which is helpful to decrease the risk of sensitization of 316L stainless steel. With the
contact length increase, the transverse stress is decreased. Further increase of the contact length has no
positive effect on reducing the longitudinal stress. With the average heat transfer coefcient increase, the
transverse stress is decreased greatly while the longitudinal stress decreases slightly, and some tensile
residual stresses have been changed to compressive in some zone.
2012 Elsevier Ltd. All rights reserved.
Keywords:
Heat sink welding
Residual stress
Finite element
1. Introduction
Pressure vessels and piping are widely used in chemical, oil, and
nuclear industries, etc [1]. To manufacture a cylindrical or spherical
pressure vessel, welding should be used to form a closed container
to hold gases or liquids at an operating pressure [2,3]. Therefore,
a lot of welding joints, such as longitudinal weld, transverse weld,
llet weld, etc, are widely generated in a pressure vessel. Due to the
local heating and cooling, residual stresses are generated in the
weld [4e6], which have a great effect on cracking [7e10], corrosion
[11e13], fatigue [14e16], etc. A lot of pressure vessels are put into
use without any stress-relief; therefore the residual stresses have
been a serious threat to the safety. Therefore, welding residual
stresses have been received a lot of attention during the past
decade [17e19]. The driving force is that the modern structural
integrity assessment procedures (BS7910, R6 and API RP-579)
require more accurate information on the weld residual stress
state to give a more realistic assessment [20e22]. Experimental
methods including hole-drilling [19], X-ray [23] and neutron
diffraction [24,25] are widely used to measure the welding residual
stress. With the computer technology development, nite element
W. Jiang et al. / International Journal of Pressure Vessels and Piping 92 (2012) 56e62
57
P2
3
2
1
P1
Fig. 2. Sketching of the welding joint.
Table 1
Physical properties for 316L base metal and 316L weld metal [41].
Temperature
( C)
K W/m/C
a (106
E (GPa)
mm/mm/C)
0
10
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
Weld
Parent
Weld
Parent
488
502
520
537
555
572
589
589
589
589
589
589
589
589
589
492
502
514
526
538
550
562
575
587
599
611
623
635
647
659
14.12
15.26
16.69
18.11
19.54
20.96
22.38
23.81
25.23
26.66
28.08
29.50
30.93
32.35
33.78
168.2
164.1
158.3
152.0
144.9
136.9
127.7
117.4
105.8
92.8
78.3
62.4
44.5
23.4
1.6
195.6
191.2
185.7
179.6
172.6
164.5
155.0
144.1
131.4
116.8
100.0
80.0
57.0
30.0
2.0
14.56
15.39
16.21
16.86
17.37
17.78
18.12
18.43
18.72
18.99
19.27
19.53
19.79
20.02
20.21
58
W. Jiang et al. / International Journal of Pressure Vessels and Piping 92 (2012) 56e62
Table 2
0% Proof stress for 316L parent metal [41].
23
210
275
150
550
112
750
95
800
88
900
69
1100
22.4
1400
2.7
p
6 3ff Q 3x2 =a2 3y2 =b2 3zvtz0 2 =c2
1
pe
qx; y; z; t
e
e
abc1 p p
Table 3
0% Proof stress for 316L weld metal [41].
Temperature ( C)
0% Proof stress (MPa)
20
250
275
216
525
196
700
143
850
88
1000
48
1400
2.7
bottom face of welding plate and the cooling water. When cooling
by water owing over the surface of steel, the average heat transfer
coefcient of 1000 W/m2 C [40] could be applied on the surface S
marked in Fig. 2. In fact, this average heat transfer coefcient is
inuenced by a lot of factors including the type of cooling media,
owing rate, dimension of the half pipe, temperature, etc. Therefore the effect of this average heat transfer coefcient on residual
stress is discussed in the following.
3.2.2. Simulation of weld heating
A nonlinear heat transfer analysis was carried out to obtain the
time dependent temperature eld induced by the multi-pass
welding. In the thermal analysis, the weld heating process is
simulated by applying a heat source of double ellipsoidal
a
With heat sink
Without heat sink
200
150
100
50
0
10
20
30
40
200
150
100
50
0
-50
0
10
20
b
Longitudinal stress (MPa)
100
0
-100
40
50
400
With heat sink
Without heat sink
300
200
30
Distance (mm)
400
300
50
(2)
Where ff and fr are parameters which give the fractions of the heat
deposited in front and the rear parts, respectively. Note that
ff fr 2.0. Here it is assumed that ff is 1.5 and fr is 0.5, which is
based on the fact that the temperature gradient in the front leading
part is steeper than in the tailing edge. Q is the power of the
welding heat source. z0 is the position of the heat source in
z-direction when t is zero. The heat source of double ellipsoidal
distribution for the moving welding arc is modeled by a user
subroutine DFLUX in ABAQUS compiled by FORTRAN program.
The thermal effects due to solidication of the weld pool are
modeled by taking into account the latent heat for fusion. The value
-100
Distance (mm)
p
6 3fr Q 3x2 =a2 3y2 =b2 3zvtz0 2 =c2
2
pe
qx; y; z; t
e
e
abc2 p p
-50
-100
(1)
Temperature ( C)
0% Proof stress (MPa)
200
100
0
-100
-200
-200
0
10
20
30
40
50
Distance (mm)
Fig. 4. Residual stress along P1 with and without the use of heat sink.
10
20
30
40
Distance (mm)
Fig. 5. Effect of heat sink on residual stress along P2.
50
W. Jiang et al. / International Journal of Pressure Vessels and Piping 92 (2012) 56e62
of the latent heat is 300 J/g. The liquidus and the solidus temperature are 1400 C and 1375 C, respectively. To account for heat
losses, convection and radiation are both taken into consideration.
In ABQUS, the simulation of weld metal deposition can be
achieved by Element Add and Remove technology, which is similar
to Element Birth and Death technology in ANSYS. Before welding,
the weld metal elements are removed. Once the welding starts, the
welded pass is added with strain free and heated, then it is cooled
down until the next weld pass cycle begins. The temperature
history of all the nodes is stored in a le for the subsequent residual
stress calculation. The material properties relevant to thermal
analysis are density, specic heat capacity, latent heat capacity, and
solidus/liquidus temperatures.
ts
59
(3)
ts
b2500
Temperature ( C)
2000
1500
1000
500
0
10
15
20
25
30
35
Time (s)
2500
1500
Temperature ( C)
Temperature ( C)
2000
1500
1000
500
0
1000
500
0
0
500
1000
1500
2000
2500
1510
Time (s)
1520
1530
1540
Time (s)
1550
1560
W. Jiang et al. / International Journal of Pressure Vessels and Piping 92 (2012) 56e62
a
Transverse stress (MPa)
away from the weld center, and then changes to compressive stress
at 16 mm. After the heat sink is used, the longitudinal stress is also
decreased and the peak value has been decreased to 288 MPa. And
some longitudinal stresses are changed to compressive. But the
longitudinal stress near the root is increased from 180 MPa to
270 MPa.
Fig. 5 shows the effect of heat sink on residual stress along P2.
Without the heat sink, the transverse stress is increased gradually
from the weld center and reaches the peak (182 MPa) at heat
affected zone (HAZ), and then it is decreased away from the HAZ.
After the heat sink is applied, transverse stress in the weld zone is
decreased slightly. At the case without heat sink, a maximum of the
longitudinal stress, 360 MPa, is generated in the weld metal. Then it
is decreased away from the weld metal. After the heat sink is
applied, the peak of longitudinal stress is decreased to around
290 MPa.
The above analysis clearly shows that the heat sink has a function to reduce the residual stress. Due to the application of heat
sink, the peak stress has been reduced, and the longitudinal stress
in the weld surface becomes more uniform. Therefore the heat sink
has a role to reduce the risk of crack generation.
Fig. 6 shows the welding temperature cycle of a node in the
center of the second weld pass. It is clearly shown that the node
undergoes two heating cycles. One is caused by the weld heating
itself, and the other is caused by the third welding. The peak
temperature without heat sink is 2500 C, while it is decreased to
2200 C when the heat sink is applied. The model with heat sink
has quicker cooling rate that that without heat sink, as shown in
Fig. 6(b) and (c). The heat sink can decrease the maximum
temperature in the weld pool and increase the cooling rate, which
leads to residual stress decrease.
The austenitic stainless steel 316L could be sensitized around
850e400 C, which will leads to intercrystalline corrosion. Therefore it is very important to decrease the dwell time around
850e400 C. At the case without heat sink, it takes 13 s to cool from
850 C to 400 C, but it just takes 6.5 s when the heat sink is used, as
shown in Fig. 6. During the third welding, this node suffers another
peak temperature of 1644 and 1541 C without and with heat sink,
respectively. During the cooling from 850 to 400 C, it takes about
31 s and 11.4 s with and without heat sink welding, respectively. It
is obviously shown that the heat sink is helpful to decrease the risk
of sensitization of 316L, leading to a decrease of the risk of the
intercrystalline corrosion.
180
10mm
15mm
35mm
135
90
45
0
0
10
20
30
40
50
Distance (mm)
b
Longitudinal stress (MPa)
60
300
10mm
15mm
35mm
200
100
0
-100
-200
10
20
30
40
Distance (mm)
Fig. 7. Effect of contact length on residual stress.
50
W. Jiang et al. / International Journal of Pressure Vessels and Piping 92 (2012) 56e62
200
150
100
50
1000
1500
3000
0
-50
-100
10
20
30
40
50
Distance (mm)
61
300
1000
1500
3000
200
Acknowledgments
100
0
-100
-200
0
10
20
30
40
(1) It is found that the heat sink technology can decrease the
residual stress greatly. Compared to the model without heat
sink, about 20% of the peak longitudinal stress has been
reduced.
(2) The heat sink increases the weld cooling rate. It decreases the
dwell time during the cooling from 850 C to 400 C, which is
helpful to decrease the risk of sensitization of 316L stainless
steel.
(3) With the contact length increase, the transverse stress is
decreased. Further increase of the contact length has no
obvious effect on reducing the longitudinal stress.
(4) With the average heat transfer coefcient increase, the transverse stress is decreased greatly while the longitudinal stress
decreases slightly, and some tensile residual stresses have been
changed to compressive in some zone.
50
Distance (mm)
Fig. 8. Effect of the average heat transfer coefcient on residual stress.
62
W. Jiang et al. / International Journal of Pressure Vessels and Piping 92 (2012) 56e62
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