5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December

12 th -14th, 2014, IIT

Guwahati, Assam, India

EXPERIMENTAL AND ANALYTICAL STUDY OF THERMALLY

INDUCED RESIDUAL STRESSES FOR STAINLESS STEEL GRADE
USING GMAW PROCESS
M.N.Chougule1*, S.C.Somase2

1*Sinhgad Institute of Technology, Lonavala, Pune-410401, chougulemn@gmail.com

2Sinhgad Institute of Technology, Lonavala, Pune-410401, sgrsomase@gmail.com

Abstract
Gas metal arc welding (GMAW) controls the metal from the wire rod by developing the arc as well as by
controlling the input process parameters. High heating at a one location during welding and further rapid cooling
generates residual stress and distortion in the weld and base metal. In the last few decades, various research efforts
have been directed towards the control of welding process parameter aiming at reducing residual stress and
distortion they are strongly affected by many parameters like structural, material and welding parameters. Such
welding failure can be minimized by controlling the weld heat input. The distribution of the temperature in weld
joint of AISI202 grade high strength steel is investigated by Finite Element Method (FEM) using ANSYS software
and experiment has been performed to verify the developed thermo-mechanical finite element model using the
GMAW process. Basic aim of our paper is to analyse temperature distribution and residual stresses in dissimilar
metal welded plates to avoid future failure in material because experimental process is costly. The behavior of weld
zone is affected by variation in temperature distribution, microstructure and mechanical properties of the material.
The residual stress gradient near the fusion zone is higher than in any other location in the surrounding area.
Because of this stress gradient, cold crack at the fusion zone in high strength steel occur. The main objective of this
simulation is the determination of temperatures and stresses during and after the process. Temperature distributions
define the heat affected zone (HAZ) where material properties are affected. Stress calculation is necessary because
high residual stresses may be caused fractures, fatigue which causes unpredictable failures in regions near the weld
bead region.
Keywords: GMAW, FEM, Transient Thermo-mechanical simulation, residual stress.

1 Introduction understand the effects on the structure of the weldment.

Welding is extensively used in the construction of
shipbuilding, chemical, automotive, power generation,
and electronic industries. Welding is an effective and
reliable metal fabrication process which is widely used
in various industries. The metal deposited develops the
weld bead and the mechanical properties depend upon
the quality of the weld bead. Compositions of material
and temperature variations in welds and parent metals
have important effects on residual stresses developed,
deformation, microstructure and mechanical properties
like hardness and tensile strength etc. of the material.
During the welding process, the thermal stresses are
generated in the specimen causing distortion and change
in the shape. The residual stresses and deformation are
developed due to non-uniform distributions of plastic
and thermal strains. These consequences deteriorate the
welding quality and affect the production life in the
places where welding steels are used. Therefore, many
researchers try to develop the algorithms and
methodologies to simulate the complete process to
H. Yu et al. [2003] investigated the temperature
distribution of aluminum plates welded by the gas
tungsten arc. The steady state temperature profiles of
the welded plates were solved by finite difference
method. An increase in the heat input is resulting in the
increasing temperature of welded plates and an increase
in welding speed produces the opposite effect. L.
Yajiang et al. [2004] done work on FEA of residual
stress in the welding zone of high strength steel. They
found residual stress goes up to 800-1000 MPa and it is
500-600 below weld. They found that residual stress in
the direction of width of test plate has highest influence
on the formation of cold crack. S. Naser et al. [2004]
found that high residual tensile stresses reaching the
yield limit at room temperature are produced close to
the weld line after cooling of the plate and residual
stress distribution along any transverse section are same
except at the edges. It is found that as the weld speed
decreases, the temperature inside the plate increases and
the residual stresses reaching the yield limit are

674-1
Experimental and Analytical Study of Thermally Induced Residual Stresses for Stainless Steel Grade Using Gmaw Process
produced in wider areas along the welded area. M
Sundar et al. [2005] assessed residual stress and
distortion in welding by FEM. They concluded that
transverse residual stresses are high near the weld and
reduces as it moves further. This is because yield force
immediately after welding is very low and part of
specimen near the weld deform plastically under very
low external load. P Biswas et al. [2009] observed that
temperature distribution and angular distortions
obtained through the finite element analysis and those
obtained from experimental measurements compared
fairly well with variation of 5-10 percent with maximum
Temperature and distortions.
A. Cardona et al. [2011] implemented models
include a moving heat source, temperature dependence
of thermo physical properties, elasto-plasticity, non-
steady state heat transfer, and mechanical analysis. The
thermal analysis is performed separately and uses
thermal history to perform mechanical analysis at each
time step. N Akkus et al. [2011] performed thermo
mechanical analysis of arc welded joint by FEM. After
comparing simulation results with the experimental
results, they found that both the results are nearly same
but experimental procedure is costly and time
consuming. They concluded that by the usage of the
simulation in the welding, errors can be avoided and
welding quality can be increased and also simulation
can be applied to complex products.
R. Kovacevic et al. [2011] carried out a numerical
and experimental study of thermally induced residual
stress in the hybrid laser- GMA welding process. They
observed that higher residual stresses is distributed in
the weld bead and surrounding HAZ and found that an
increase in welding speed can reduce the residual stress
concentration in the weld specimen.
To avoid the failure of material it is important task
to predetermine these problems before welding process
is to be done. One of the methods for prediction of
welding process is "try and see" method which is time
consuming and costly. Therefore, there is need of such
method which will save time and money in another
sense it will give best results in short duration. So FEM
is usually preferred to monitor and predict the welding
process. Our basic aim is to analyse temperature
distribution and residual stresses in dissimilar metal
welded plates to avoid future failure in material.
2 Procedure
2.1 Experimental process description
The experiment was carried on a semi-automatic
GMAW machine for welding of AISI 202 material
using filler wire of AISI 308L. It is 3 phase, 50Hz
frequency, 300A current, air cooling machine of size
760x313x500mm. The trolley is used to travel work
piece which will move at perfect path with constant
speed. The gas flow rate in the welding can be adjusted
and measure with the help of the flow meter. Also, wire
feed rate, welding voltage and current are adjusted in
the GMAW machine and the speed of the welding can
be adjusted and measured. The welded test work piece
had the dimensions of 250x100x10 mm. The groove
angle between welded pieces is 600. The thermocouples
arrangement on the welding plate for measuring
temperature distribution is as shown in Fig.1.The K type
thermocouple is used for measuring the temperature
distribution in the plate after the welding. The tip
diameter of thermocouple is 1.5mm and wire length is
300mm. The tip of three thermocouples is kept at three
different locations on a top surface in a vertical position
and temperature is indicated by temperature indicator.
Fig.1 Experimental set up
2.2 Simulation procedure using ANSYS
The governing equation for heat conduction in a
solid is,
𝜕 𝜕𝑇 𝜕 𝜕𝑇 𝜕 𝜕𝑇 𝜕𝑇
(𝐾 ) + (𝐾 ) + (𝐾 ) + 𝑄 = 𝜌𝐶𝑠
𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑧 𝜕𝑧 𝜕𝑡
In FEM residual stresses are calculated with the
help of virtual work principle. In this method, one
considers infinitesimal node displacements {δ} imposed
onto the body. This causes an external total virtual work
and it is equal to the total internal virtual work and it is
defined by stresses {σ} and strains {ε}. By using FEM,
strain displacement can be expressed briefly as follows,
{𝜀} = [𝐵]{𝛿}𝑒
Where [B] is the strain–displacement matrix
{δ}e is the displacement vector for an element.
The stress–strain relation is as follows,
{σ} = [𝐶]{𝜀}
Where [C] is the elasticity matrix.
The simulation procedure consists of three distinct
steps, i.e. build the model, apply loads and obtain the
solution and review the results. Fig. 2 shows the
detailed sequential coupled thermo-mechanical
simulation strategy adopted.
The welded test workpiece having dimensions of
250x100x10 mm shown in detail in Fig.3 (b). The
groove angle between welded pieces is 600. By using
ANSYS model is prepared as shown in Fig. 3 (a).
674-2
5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 th -14th, 2014, IIT
Guwahati, Assam, India

Temperatures Thermal Thermal

(0C) conductivity expansion
(W/m-0C) coefficient
(x10-6/0C)
AISI AISI AISI AISI
202 308L 202 308L
100 16.2 16.1 17.5 17.2
200 17.5 17.3 17.8 17.6
300 19 18.7 18.4 17.8
400 20.8 20.1 18.8 18.1
500 21.6 21.6 19.2 18.4
600 21.9 23.2 19.6 18.8
700 22.2 24.6 19.9 19.1
800 22.6 26.3 20.2 19.6
900 23.2 28.2 20.4 20
1000 23.6 29.5 20.6 20.3
1100 23.9 31.8 20.8 20.6
The model with the FE mesh is generated. The eight-
node brick elements with linear shape functions are used
in meshing the model. The SOLID70 and SOLID185
elements have been used for meshing. SOLID70 has a
three-dimensional thermal conduction capability. The
element has eight nodes with a single degree of
freedom, i.e. temperature at each node. The element is
applicable to a three-dimensional steady-state or
transient thermal analysis. If the model containing the
conducting solid element is also to be analyzed
structurally, the element should be replaced by an
equivalent structural element (such as SOLID185).
Total number of elements after meshing are 5992.
A molten metal is poured with temperature of 13850C
Fig. 2 Flowchart of simulation procedure (melting point temperature of filler material AISI 308L)
between the plates along the center line [5], also
mention the surrounding temperature of 280C to
consider room temperature. The simulation has been
carried out for thermal analysis in a time period of 1000
seconds.

(a) Simulation Model

(a) Thermal (b) Structural

Fig.4 Boundary Conditions

The numbers of sub steps are 5. The time at the end

of load step is 1000 second. The time step size is 200
(b) Bead Geometry seconds. The model with thermal boundary conditions
Fig.3 Model developed. has been shown in Fig.4 (a). Clamping has done at the
end surfaces to avoid distortion while welding of plates.
As effect of clamping at both end surfaces, vertical
Table 1: Thermal material properties displacement of plates due to welding force is

674-3
Experimental and Analytical Study of Thermally Induced Residual Stresses for Stainless Steel Grade Using Gmaw Process
constrained. The model with structural boundary
condition has been shown in Fig.4 (b).
3 Results and discussion
As shown in Fig.5 (a) cross sectional view of weld
bead with three points at three different locations (at
weld zone, heat affected zone and base metal) at the top
surface of the weldment and the distance from the
centre line. The temperature distribution curve is plotted
at these three locations with respect to time as shown in
the Fig. 5(b). It is observed that high temperature exist
at the weld zone where melting occurs by arc heating.
When the welding process is done, welded specimen is
cooled up to the room temperature (28 0C) in air.
Temperature value decreases when further moving away
from the centre line of the weldment. Fig.5 (b) shows
that the maximum temperature reaches to 13850C at
weld zone (at point P3). Similarly at point (P1 and P2)
on parent plate maximum temperature values are
decreases.
(a) (b)
Fig.5 Temperature distribution at various
locations (a) cross sectional view of weld bead
(b) Temperature distribution curve
The deposition of material is modeled using an
element “birth and death” technique. For obtaining
“death element” effect ANSYS have to deactivate
element by multiplying their stiffness by a huge
reduction factor and to obtain the “birth element” effect,
again reactivates the “death element” by allowing its
stiffness mass, element loads, etc. return to their original
values. Fig.6 (a) shows shear stress developed along XY
plane shows that on one side compressive and on
another side tensile stresses are developed along XY
plane which is having maximum value at weld bead.
Fig.6 (b) indicates compressive and tensile stress
developed on each side of weld bead on XZ plane.Fig.7
(a-d). Shows the stress distribution along weld bead at
three different paths at the top surface of weld bead at
z=20, 50 and 80 mm. Fig.7 (a) shows that maximum
compressive stresses are formed near the weld bead.
The intensity of stresses are more at the middle of
weldment and nearly same at 20mm and 80mm. The
same amount of tensile stresses is induced near end
surfaces due to clamping. At z=50mm, compressive
residual stresses of about 300 MPa near the weld bead
are developed. Fig. 7(b) shows that compressive normal
stresses are developed at end surfaces due to clamping.
Similarly compressive stresses are more at weld bead
and tensile stresses are developed on HAZ. Residual
stresses of range 50-100 MPa are developed at the weld
bead. Fig.7(c) shows that more compressive stresses are
induced near the weld bead. Compressive stresses up to
470 MPa are developed at the weld zone. Similarly
tensile stresses developed in the parent material zone are
about 150 MPa. The little amount of compressive
stresses are induced near the end surface of the
weldment. The tensile and compressive stresses are
maximum at middle of the weldment. Fig.7 (d) shows
that all the stresses are tensile in nature and it is
maximum at weld bead and minimum at the end of the
weldment. Von misses stresses developed at the weld
bead are up to 380 MPa.
Fig. 8(a-d) shows the stress distribution across the
weld bead at the middle section (z = 50mm) along
thickness. Fig.8 (a) shows that residual compressive
stresses are maximum near weld bead zone and tensile
stresses are observed in base material near the end
surfaces. The end portion of the weldment is free from
stresses. The residual compressive stress of nearly 300
MPa is developed in the weld zone. Fig. 8(b) shows that
compressive stresses are developed at weld bead.
Residual compressive stresses of 50-150 MPa are
developed at the weld zone. Also little compressive
stresses are developed near end surfaces. Stresses
induced at all locations are almost same. Fig. 8(c) shows
that longitudinal stresses at middle, top and bottom
surface are same. More compressive stresses are
developed near the weld bead up to 500 MPa. Also
tensile stresses induced in parent material. Fig. 8(d)
shows that all the stresses are tensile in nature and it is
maximum at weldment and minimum at the end of the
weldment. The tensile stresses are goes on decreasing as
move away from weld bead zone. Von mises stress
developed in entire weldment is nearly same. From Fig
7(a-d) and 8(a-d), it is observed that at weld zone i.e.
HAZ compressive stresses are developed which are
more than yield strength but less than ultimate strength
of material. Hence failure may occur at the weld zone if
maximum loading is done at this zone.
674-4
5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 th -14th, 2014, IIT
Guwahati, Assam, India

(a) (b)
Fig.6 Residual stress distribution: (a) x–y plane shear stress SXY, (b) x–z plane shear stress SXZ

(a) (b)

(c) (d)
Fig.7 Stress distribution along weld bead at three different paths at the top surface of weld bead obtained by GMA
welding: (a) transverse stress SX, (b) normal stress SY, (c) longitudinal stress SZ, and (d) Von Mises stress SEQV.

(e) (f)

(g) (h)
Fig.8 Stress distribution across the weld bead at the middle section (z = 50mm) along thickness: (a) transverse
stress SX, (b) normal stress SY, (c) longitudinal stress SZ, and (d) Von mises stress SEQV.

674-5
Experimental and Analytical Study of Thermally Induced Residual Stresses for Stainless Steel Grade Using Gmaw Process

4 Comparison of Experimental and 4) The residual stresses developed along longitudinal

Simulation Results direction are high near the weld bead and reduces as we
moves away from weld bead.

References
H. Yu(2003), “Thermal analysis of welding on
aluminium plates”, Journal Of Marine Science And
Technology, Vol. 11, No. 4, pp. 213-220.
Li Yajiang(2004) “Finite element analysis of residual
stress in the welded zone of a high strength steel”,
Indian academy of sciences, vol. 27 no. 2, pp. 127-132.
S. Naser(2004), “Transient variations of thermal stresses
and the resulting residual stresses within a thin plate
during welding processes”, Journal of thermal Stresses,
Fig.9 Comparison of simulation and experimental Taylor And Francis Group, Vol. 27, pp. 671-689.
thermal profiles. M Sundar, G Nandi, A Bandyopadhyay, S C Roy(2005)
“Assessment of residual stress and distortion in welding
by finite element method”, International conference on
Fig.9 shows the simulation and experimental
mechanical engineering 2005, Vol.1, pp. 1-6.
temperature distribution profiles. The experimental
P. Biswas( 2009 ) “Numerical and experimental study
points (thermocouple position) for the thermal history,
on prediction of thermal history and residual
we're located at the weld bead on the top surface of
deformation of double-sided fillet welding”, J.
horizontal plate. It is observed from figure that there is a
Engineering Manufacturing, Vol. 224, pp. 125-134.
close agreement between the simulation and
Alberto Cardona(2011), “Finite element modeling of
experimental thermal profile. The FEM model predicts a
welding processes”, Applied Mathematical Modelling
little more temperature than the measured peak
35 688–707
temperature. A small temperature gradient difference is
N.Akkus, E. Toptas(2011), “Thermo-mechanical
due to the effects of radiation in the experiment. In this
analysis of arc welded joint by finite element method”,
study, an experiment was conducted to verify the
AWST,Vol. 20, pp. 24-25.
simulated results. As the simulation thermal profiles are
Fanrong Kong, Junjie Ma, Radovan Kovacevic( 2011),
nearly matching with experimental results it can be
“Numerical and experimental study of thermally
predicted that stress profiles got by simulation must be
induced residual stress in the hybrid laser–GMA
correct.
welding process”, Journal of material processing
technology, USA,Vol. 123, pp.1102-1111.
5 Conclusion A. Anca, “3D-Thermal-Mechanical simulation of
According to results in this study, the following welding processes”, Mecanica Computational, Vol. 23,
conclusions can be drawn: pp.2301-2318.
1) There is a close agreement between the simulation
and experimental thermal profile. As the simulation
thermal profiles are nearly matching with experimental
results, it can be predict that stress profiles and
deformation got by simulation must match with
experimental profile.
2) There are different experimental methods for
measuring residual stresses developed in welded parts
such as hole method, X- ray diffraction method, etc. But
experimental measurements are costly, require
equipment and time consuming. However, finite
element package is enough for getting results with
negligible variation to that of experimental results.
3) By using Thermal and Mechanical stress reliving
techniques, balancing of residual stresses can be
possible.

674-6