TY - JOUR A1 - Heinze, Christoph A1 - Schwenk, Christopher A1 - Rethmeier, Michael T1 - Numerical calculation of residual stress development of multi-pass gas metal arc welding JF - The journal of constructional steel research N2 - In various applications, welding-induced residual stresses have a substantial impact on the integrity of welded constructions. Tensile residual stress can promote stress-corrosion cracking, brittle fracture, and reduces the fatigue life in service, as well as influences component design due to critical stress concentrations within the component. In the present paper, a six bead multi-pass gas metal arc weld of 20 mm thick structural steel S355J2+N is experimentally and numerically investigated. The studies include transient 2D and 3D numerical calculations which consider temperature-dependent material properties, phase transformations, 'thermal' tempering, transformation plasticity, volume change due to phase transformation, an elastic–plastic material model, and isotropic strain hardening. The experimentally determined and calculated residual stresses are in a good agreement. Furthermore, the influence of the preheat and interpass temperature on welding-induced residual stresses is shown in the present investigation. KW - Welding simulation KW - Gas metal arc welding KW - Welding-induced residual stress KW - Multi-pass welding KW - Sensitivity analysis PY - 2012 DO - https://doi.org/10.1016/j.jcsr.2011.08.011 SN - 0143-974x VL - 72 SP - 12 EP - 19 PB - Elsevier CY - Oxford AN - OPUS4-25629 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Heinze, Christoph A1 - Schwenk, Christopher A1 - Rethmeier, Michael T1 - Effect of heat source configuration on the result quality of numerical calculation of welding-induced distortion JF - Simulation modelling practice and theory N2 - The results of numerical welding simulations strongly depend on its temperature field. In the present paper, the temperature field of a pulsed gas metal arc weld of structural steel S355J2+N (ASTM A572 Gr. 50) with a thickness of 5 mm is experimentally and numerically investigated. In the case of temperature field validation, volumetric Gauss and double-ellipsoid Goldak heat sources are applied. Additionally, different heat source configurations, including adaptations of thermal conductivity, are analyzed regarding their influence on the calculation of welding-induced distortion. The investigations clarify the influence of heat source configurations on the calculated results, thus, contribute to an improved prediction of welding-induced distortion. KW - Welding simulation KW - Heat source calibration KW - Gas metal arc welding KW - Sensitivity analysis KW - Distortion KW - Schweißsimulation KW - Verzug KW - Wärmequellenkonfiguration KW - Sysweld KW - Heat source configuration PY - 2011 DO - https://doi.org/10.1016/j.simpat.2011.09.004 SN - 1569-190X VL - 20 IS - 1 SP - 112 EP - 123 PB - Elsevier CY - Amsterdam [u.a.] AN - OPUS4-24684 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Heinze, Christoph A1 - Schwenk, Christopher A1 - Rethmeier, Michael T1 - The effect of tack welding on numerically calculated welding-induced distortion JF - Journal of materials processing technology N2 - A single-layer pulsed gas metal arc weld of structural steel S355J2+N with a thickness of 5 mm is experimentally and numerically investigated. Two tack welds are considered in the numerical simulation into two different ways. First, the tack welds are represented by elements belonging to the initial material. This implies that the 'tack weld material' was not exposed to any thermal load or phase transformation before actual welding was performed. The weld seam is shortened and there is an influence on the stiffness of the whole structure affecting the calculation result. Secondly, the tack welds were simulated as conducted in the experimental welding procedure. The cases considering tack welding are compared to a simulation neglecting tack welding and to the experimental results. The influence of tack welds on the calculated welding-induced distortion is clarified and a contribution to an improved simulation-based prediction of welding-induced distortion is possible by modeling tack welding according to the realistic fabrication procedure. KW - Welding simulation KW - Welding-induced distortion KW - Gas metal arc welding KW - Tack welding PY - 2012 DO - https://doi.org/10.1016/j.jmatprotec.2011.09.016 SN - 0924-0136 SN - 1873-4774 VL - 212 IS - 1 SP - 308 EP - 314 PB - Elsevier CY - Amsterdam AN - OPUS4-24820 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Caron, J. A1 - Heinze, Christoph A1 - Schwenk, Christopher A1 - Rethmeier, Michael A1 - Babu, S. S. A1 - Lippold, J. T1 - Effect of continuous cooling transformation variations on numerical calculation of welding-induced residual stresses JF - Welding journal N2 - Continuous cooling transformation (CCT) behavior affects the transient state of material properties employed in a numerical welding simulation, having a direct influence on the developing stress state. Three different CCT diagrams for S355J2 steel were employed to understand the influence of variations in CCT behavior on the numerical calculation of welding-induced residual stresses. The CCT diagrams were constructed from transformation data contained in the Sysweld software database, measured dilatometric data from Gleeble experiments, and transformation data calculated from the JMatPro software. The calculated transverse and longitudinal residual stress distributions provided a qualitative correction only in comparison to experimental measurements, with the largest deviation occurring near the weld interface. Overall, the results indicate a weak dependency of the calculated residual stresses due to anticipated CCT variations. The most significant effect on the calculated residual stresses was shown to be related to the proportion of formed martensite. It is suggested that CCT data of approximate accuracy is sufficient for reliable calculation of welding-induced residual stresses. KW - Continuous cooling transformation diagrams KW - Residual stresses KW - Gas metal arc welding KW - C-Mn steels KW - Welding simulation KW - Schweißsimulation KW - Eigenspannungen KW - Martensitbildung KW - Sensitivitätsanalyse KW - Sysweld KW - Martensite kinetic KW - Sensitivity analysis PY - 2010 SN - 0043-2296 SN - 0096-7629 VL - 89 SP - 151-s - 160-s PB - American Welding Society CY - New York, NY AN - OPUS4-21444 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Heinze, Christoph A1 - Schwenk, Christopher A1 - Rethmeier, Michael T1 - Influences of mesh density and transformation behavior on the result quality of numerical calculation of welding induced distortion JF - Simulation modelling practice and theory N2 - Welding simulation is a powerful, cost-efficient tool to predict welding induced distortion. Nevertheless, effects on calculation result quality are often unknown, thus, sensitivity analyses should be performed to evaluate the influences of certain parameters on distortion development. In the present paper, a single-layer gas metal arc (GMA) weld of 5 mm thick structural steel S355J2+N is experimentally and numerically investigated. Subsequent to welding, the numerical modeling begins with a mesh analysis based on modal analyses. Hereby, the influence of different coarsening methods and element edge length (EEL) in welding direction on the deformation behavior or the stiffness of the discrete geometry is the focus of the analysis. Secondly, phase transformations in structural steels such as S355J2+N are decisive for final product properties. The sensitivity of welding-induced distortion is examined regarding different continuous cooling transformation (CCT) diagrams for S355J2+N. The present investigations deal with different relevant influences on numerical calculation of welding-induced distortion. The quality and quantity of these effects are clarified based on the experimental and numerical set-up employed. Consequently, prediction of welding-induced distortion is possible and potential for pre-production optimization is present. KW - Welding simulation KW - Gas metal arc welding KW - Welding-induced distortion KW - Mesh analysis KW - CCT sensitivity PY - 2011 DO - https://doi.org/10.1016/j.simpat.2011.05.001 SN - 1569-190X VL - 19 IS - 9 SP - 1847 EP - 1859 PB - Elsevier CY - Amsterdam [u.a.] AN - OPUS4-23874 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -