Int J Adv Manuf Technol (2009) 41:250–258
DOI 10.1007/s00170-008-1487-4
ORIGINAL ARTICLE
Finite element analysis of the residual stresses in T-joint fillet
welds made of similar and dissimilar steels
Kyong-Ho Chang & Chin-Hyung Lee
Received: 9 August 2007 / Accepted: 19 March 2008 / Published online: 23 April 2008
# Springer-Verlag London Limited 2008
Abstract In this paper, weld residual stress analyses are
performed for T-joint fillet welds made of similar and
dissimilar steels. Three-dimensional uncoupled thermo-
mechanical finite element model which can accurately
capture residual stresses in a weld piece is developed in
order to predict the residual stress states in the fillet-welded
T-joint. Results show that the maximum longitudinal
residual stresses near the weld toes of the similar steel
welds increase with increasing yield stress of the steel
welded. For the dissimilar steel welds, the overall trend,
shape and magnitude of the residual stress profiles in flange
and web are similar to those of the corresponding similar
steel welds despite the slight difference between the
residual stresses in parts at which the flange and web come
in contact with each other.
Keywords T-joint fillet welds . Similar and dissimilar steel
welds . Residual stresses . Finite element analysis . Weld toe
1 Introduction
As the stories of buildings are getting higher and the spans
of bridges are getting longer, there are greater demands for
high performance and high strength steel [1, 2]. Likewise,
the fabrication of structural members using dissimilar steels
makes it possible for steel structures to be lighter and more
K.-H. Chang : C.-H. Lee (*)
Department of Civil and Environmental Engineering,
Chung-Ang University,
221, Huksuk-dong, Dongjak-ku,
Seoul 156-756, Korea
e-mail: ifinder@hanmail.net
economical [3]. Typically, metallurgical joints made by a
fusion welding process such as flux cored arc (FCA)
welding are used to fabricate the structural member. The
types of welded joints can be divided into five basic
classes: butt, fillet, corner, lap and edge [4]. Among the
welded joints, T-joint fillet welds are extensively employed
in various engineering applications. Actually, T-joint fillet
welds made of similar and dissimilar steels are the most
common type of joint used in the fabrication of structural
members in steel girder bridges.
Welding processes including T-joint fillet welding con-
sists of melting and solidification of weld metal and base
metal in localized fusion zone by a transient thermal heat
source. Due to the intense concentration of heating in
localized zone and subsequent cooling during welding,
temperatures in the vicinity of the weld are not uniform but
change with distance from the weld centreline. The
temperature gradients cause the local plastic strains to be
formed, thus leading to inevitable residual stresses there.
Residual stresses caused by welding can have various
kinds of influence on the welded structure, e.g., increasing
the susceptibility of a weld to fatigue damage, stress
crossing cracking and fracture [5]. Moreover, residual
stresses developed in T-joint fillet welds made of dissimilar
steels are presumably different from those of similar steel
welds in magnitude. Residua stresses are unavoidable, and
the effects on welded structures are cannot be disregarded.
Therefore, it is very important to clarify the characteristics
of residual stresses in T-joint fillet welds made of similar
and dissimilar steels to assure the sound design and safety
of the structure. However, accurately predicting weld
residual stresses is a hard task since the thermal and
mechanical behaviour during welding includes localized
heating, temperature dependence of material properties and
Int J Adv Manuf Technol (2009) 41:250–258
moving heat source, etc. Accordingly, finite element (FE)
simulation has become a popular tool for the prediction of
weld residual stresses [6–8].
Over the last two decades or so, a number of FE analyses
have been performed to predict residual stresses in T-joint
fillet welds made of similar steels [4, 9, 10]. Moreover,
recently, residual stresses in dissimilar steel welds have
been investigated through experimental or numerical
method by some studies [11, 12]. However, these works
were confined to butt-joint welds; thus studies on the
residual stresses in T-joint fillet welds made of dissimilar
steels appear to be very lacking.
In this study, continuing the prior research [3], three-
dimensional FE simulation of T-joint fillet welding is
performed. A three-dimensional thermo-mechanical FE
model is developed to simulate the temperature fields and
the welding residual stress fields in T-joint fillet welds
made of similar and dissimilar steels. In the FE model, the
temperature-dependent material properties, work harden-
ing behaviour, and the weld filler variation with time are
taken into account. Characteristics of the weld residual
stresses, especially the longitudinal residual stresses
which are generally most harmful to the integrity of the
structure among the residual stress components, in both
similar and dissimilar T-joint fillet welds are discussed in
detail.
2 FE modelling procedure
The procedure for welding-induced residual stress analysis
in principle consists of two solution steps: thermal and
mechanical (stress) analyses. First, temperature distribution
and its history in a weld piece are computed by thermal
analysis. Then, the temperature history is employed as a
thermal load in subsequent mechanical analysis. In order to
accurately capture the temperature fields and the residual
stresses in the fillet-welded T-joint, in this work, three-
dimensional FE model is developed based on the FE code
[13–15]. The thermo-mechanical behaviour of the weld-
ment during welding is simulated using uncoupled formu-
lation since the thermal field has a strong influence on the
stress field with little inverse influence [16]. The following
subsections explain the solution steps used for the present
study.
2.1 Thermal analysis
The heat input to the work piece can be divided into two
portions. One is the heat of the welding arc, and the other is
that of the melt droplets. The heat of the welding arc is
modelled by a surface heat source with a Gaussian
distribution, and that of the melt droplets is modelled by a
251
volumetric heat source with uniform density. Heat flux
distribution at the surface of the work piece within the arc
beam radius r0 is defined by the following equation [5]:
3Q1
ðr=r0 Þ2
qð r Þ ¼ e ð1Þ
πr02
where r is the radial coordinate with the origin at the arc
centre and Q1 is the heat input from the welding arc
Q1 ¼ hIU
Q2 ð2Þ
where η represents the arc efficiency factor, I is the arc
current, U the arc voltage and Q2 is the energy induced by
high temperature melt droplets. The heat of the welding arc
is assumed to be 40 % of the total heat input, and the heat
of the melt droplets 60 % of the total heat input [17]. The
arc efficiency factor is assumed as 0.85 for the FCA
welding process used in the present analysis.
To consider the heat losses from the surface of welded
plate, both radiation and convection are assumed. During
the thermal cycle, radiation heat losses are dominant in and
around the weld pool; whereas, away from the weld pool
convection heat losses are dominant. Instead of modelling
radiation and convection heat losses separately, the total
temperature-dependent heat transfer coefficient is used by
Eq. (3) [18].
 
es ðT þ 273Þ4
ðT0 þ 273Þ4
h¼ þ hc ð3Þ
ð T
T0 Þ
where T0 =20°C
is the room temperature; σ ¼ 5:67
10
8 J m2 K4 s is defined as the Stefan–Boltzmann con-
stant. The convection coefficient (hc) is estimated using
engineering formulae for natural convection to be 15
W/(m2K) and the emissivity is defined to be e=0.2 [5],
respectively.
To account for the heat transfer due to fluid flow in the
weld pool, the thermal conductivity is assumed to increase
linearly between the solidus temperature and 3000 K by a
factor of three [5]. The liquid-to-solid phase transformation
effects of the weld pool are modelled by taking into account
the latent heat of fusion. The latent heat, solidus and
liquidus temperature are 270 J/g, 1450°C and 1500°C,
respectively.
2.2 Mechanical (stress) analysis
Rate-independent elastic-plastic constitutive equation is
considered with the von Mises yield criterion, temperature-
dependent mechanical properties and linear kinematic
252 Int J Adv Manuf Technol (2009) 41:250–258

hardening rule. The incremental form of stress-strain relation
can be written as
fds g ¼ ½Dd fdeg
fcgdT ð4Þ
 e
 p  [Dd] is divided into Dd for the elastic range and
where
Dd for the plastic range, {c} is a parameter to reflect the
stress increment due to the dependence of the physical and
mechanical properties of the material on temperature, dσ is
the stress increment, de is the strain increment and dT is the
temperature increment.
During the welding process, because the solid-state
phase transformation (Martensite transformation) [5, 19]
does not occur in the base metals and the weld metal used
in this investigation [20], the effects of volume change due
to the phase transformation on the residual stress are
negligible.
In this work, so called element “birth” and “death”
technique with respect to a group of elements representing
weld metal deposition is used to simulate the weld filler
variation with time. The thermal aspect of the technique is
to change the thermal conductivity of the relevant part of
the FE mesh corresponding to the weld metals that have not
been laid down yet with a value equivalent to that of air.
The mechanical aspect of the technique is to change the
stiffness of the FE element in welded zone with severe
reduction factor [21, 22] which the welding torch has not
and transverse released strain ey are measured. Longitudinal
residual stress σx and transverse residual stress σy can be
obtained from the following equations using measured
strains.


E
sx ¼
ex þ vey ð5Þ
1
v 2
E

sy ¼
ey þ vex ð6Þ
1
v2
where E is Young’s modulus and v is Poisson’s ratio.
Three-dimensional thermal elastic-plastic FE analysis for
the experimental model using the FE formulation explained
above has also been carried out employing the same
welding conditions and process parameters as those used
in the fabrication of the specimen. Figure 1(a) [3] and (b)
portray the longitudinal (σx) and transverse (σy) residual
stresses at a cross-section of the weld piece perpendicular to
the welding direction, respectively. The hollow symbols
represent the results of the experimental value measured by
strain gauges, the solid curve the results of the three-
dimensional analysis. The results are normalized by the
(a)
Longitudinal Residual Stress (σx/σY0)

1.6 Analysis
yet approached. Experiment

1.2

2.3 Verification 0.8

0.4
In order to confirm the accuracy of the formulation used in
this investigation, a specimen of double ‘V’ butt joint 0
welding of a thick-wall plate has been constructed, with a
-0.4
length, width and thickness of L=600 mm, W=400 mm, t=
25 mm, respectively. The base material is a mild carbon -0.8
steel (SM400) and the material information is given in Sect. 0 50 100 150 200

3.1. The joint is welded in the flat position with six passes Distance from the weld centreline (mm)
using FCA welding process with DW-100 electrode of
1.2 mm in diameter which is practically used for the (b)
welding of mild carbon steels in Korea. Details on the weld 0.8 Analysis
Transverse Residual Stress (σy/σY0)

Experiment
metal and the preparation of the specimen can be found in
[3]. 0.6

Residual stress measurements have been carried out on

0.4
the two axis strain gauge with the layering technique.
Measuring stresses by strain gauges using the layering 0.2
technique can obtain the residual stresses on the surface of
the structure to be evaluated. The detailed procedure for 0
measuring the residual stresses on the surface of the
specimen is as follows. First, strain gauges are attached -0.2
0 50 100 150 200
on the bottom surface of the specimen. The periphery of the
Distance from the weld centreline (mm)
attached strain gauges is cut into small cube with about 10
Fig. 1 Residual stresses at a cross-section of the weld piece
mm sides. Residual stresses in the small pieces are released perpendicular to the welding direction: (a) Longitudinal residual stress
by cutting the specimen, and longitudinal released strain ex distribution, (b) Transverse residual stress distribution
Int J Adv Manuf Technol (2009) 41:250–258 253

respective yield stress (σY0) of the weld metal and base (a)
metal. According to the results, the residual stress distribu-
tions computed by the FE analysis show very good
agreement with those determined by the experiment.
Furthermore, residual stress distribution calculated by
the FE analysis is compared with FE result taken by Teng et
al.’s [4]. Their investigation has computed the residual
stress distribution in T-joint fillet welds constructed with
one-pass welding and made of similar steels using three-
dimensional thermal elastic-plastic FE analysis. Details on
the analysis can be found in elsewhere [4, 9, 22]. Figure 2
depicts the longitudinal residual stress distributions across
the width of the flange. The broken line and solid line
represent the longitudinal residual stresses computed by
Teng et al. and this work, respectively. Here again, the
residual stress distribution computed by the FE analysis (b)
shows very good agreement with that determined by the Z
three-dimensional FE analysis.
Therefore, the FE formulation used here is considered
appropriate for analysing the residual stresses induced by
Y
the welding process. X

3 Residual stresses in T-joint fillet welds made of similar

and dissimilar steels

3.1 FE model

FE thermal simulation of a T-joint fillet welding process is

carried out using the FE model described in the previous
sections. Two plates are assumed to be fillet welded by one
pass welding. Figure 3(a) depicts the analysis model and
the shape of T-joint fillet welds. The length of the weld, the
Fig. 3 Analysis model: (a) Dimensions of analysis model and shape
width of the flange and height of the web are assumed to be of fillet welds, (b) Three-dimensional FE model
600, 500 and 120 mm, respectively. The plate thickness is
15 mm for the flange and 19 mm for the web. The welding
parameters chosen for this analysis are as follows: welding both sides of the web are assumed to be simultaneously laid
method, FCA welding process; heat input, 1300 J/mm; and down under the same welding conditions. This along with
welding speed, 6 mm/s, respectively. The fillet welds on the geometry allows symmetry conditions with respect to
the centreline to be assumed. The three-dimensional FE
600 Present FE model model is shown in Fig. 3(b) with eight-noded isoparametric
Longitudinal Residual Stress (MPa)

Teng et al.'s
solid elements. Due to anticipated high temperatures and
400 stress gradients near the weld, a relatively fine mesh is used
in the welding area. The smallest element size is 0.1×1.5×
200 10.0 (mm). Element size increases progressively with
distance from the weld centreline. In order to facilitate data
0 mapping between thermal and mechanical models, the same
FE mesh refinement is used with respective element types.
-200 For the thermal model, the element type is one which has
single degree of freedom, temperature, on its each node.
-400
0 20 40 60 80 100
For stress model, the element type is the other with three
Distance from the centreline (mm) translational degrees of freedom at each node. As the pipe
Fig. 2 Longitudinal residual stresses across the width of the flange is not clamped during welding, no boundary conditions
254 Int J Adv Manuf Technol (2009) 41:250–258

1/4 position
except those to prevent rigid body motion of the weld piece 2400
2/4 position
are applied. 2100 3/4 position

SM400, SM490 and SM520, the most widely used 1800

Temperature (°C)
structural carbon steels in Korea [3], have been used as the 1500
materials of choice. Temperature-dependent thermo-physical
1200
constants such as thermal conductivity, specific heat and
900
density of the materials are assumed to be the same and
given in [3]. Moreover, temperature-dependent thermo- 600

mechanical properties such as Young’s modulus, thermal 300

expansion coefficient, Poisson’s ratio and yield stress are 0

tabulated in [23] and are shown in Fig. 4.
In order to predict residual stresses in T-joint fillet welds
made of similar and dissimilar steels, two cases are
considered, i.e., one case with the flange and web made of
similar steels, and the other case with the flange fixed as
SM400 and the web changed to SM490 and SM520. For the
practical comparison, the weld metal for the similar and
dissimilar steel welds is assumed to be fixed as DW-100 and
the existence of 0.1 mm root gap is considered in all cases.
For the weld metal, only the yield stress and tensile strength
are different from those of the base metals, the other
properties are almost the same as the base metals. Thus, its
deterioration of mechanical properties with increasing
temperature is assumed to be Fig. 4(a) due to the lack of
material information especially at high temperatures.
Linear expansion coeff. α=1.2 x 10-5(1/°C)
Poisson's ratio v=0.3
800
200
σ Y : Yield Stress
0 50 100 150 200 250 300
Time (s)
Fig. 5 Thermal cycles at several locations remote from the welding
start position during the welding
3.2 Results and discussion
Results are first presented for the thermal cycles during the
welding. Temperature distributions are presented for the FE
model at the weld area. Figure 5 shows the thermal cycles
at different locations remote from the welding start position.
The curve with hollow marks represents the temperature
history at the location which is 150 mm away from the start
position (1/4 position), the broken curve the temperature
history at the location 300 mm away from the start position
(2/4 position), and curve without any mark the temperature
history at the location 450 mm away from the start position
(a) (3/4 position). From the figure, it can be observed that the
maximum temperature at the weld pool is 2100°C or so.
This result agrees with the welding process in practice.
Furthermore, it is clear that the temperature histories at the
Young's Modulus

600 σU(W)
σU : Ultimate Strength three locations are almost identical. Therefore, it can be
Stress (MPa)

σ(W) : DW-100
150
σY(W)
E (GPa)

concluded that the temperature filed is steady when the

400
100 welding torch moves along the joint.
E
Results are next presented for the residual stresses
200 50
induced by the welding. From the analysis all the stress
components can be obtainable. Here, we will discuss only
0 0
0 200 400 600 800 1000 1200 1400 the relevant data. In this discussion, the profiles of
Temperature (°C)
longitudinal (acting parallel to the weld line - σx), transverse
(b) (acting perpendicular to the weld line, i.e., acting along the
800 plate width - σy) and through-thickness (acting normal to
the weld line, i.e., acting along the plate thickness - σz)
600
σU(B3)
residual stresses are predicted.
σ(B1) : SM400
Stress (MPa)

σ(B2) : SM490 Figures 6, 7 and 8 show the residual stress distributions

σU(B2) σU(B1) σ(B3) : SM520
400 at a cross-section of the flange perpendicular to the welding
σY(B3)
direction and half way through the weld length (x=300)
σY(B2)
when welding similar steels. The stress profiles are reported
200 σY(B1)
at two different depths at 1.5 mm (top-thickness) and
13.5 mm (bottom-thickness) from the top flange surface.
0
Figure 6(a),(c) show the longitudinal, transverse and
0 200 400 600 800 1000 1200 1400
Temperature (°C)
through-thickness residual stress profiles for the SM400
Fig. 4 Temperature-dependent thermo-mechanical properties of the welds, respectively. From the simulated results, it can be
materials observed that the highest tensile longitudinal residual
Int J Adv Manuf Technol (2009) 41:250–258 255

Longitudinal Stress Profile (SM400) (a) Figure 7(a),(c) show the longitudinal, transverse and
600
Depth_1.5mm through-thickness residual stress profiles for the SM490
500 Depth_13.5mm welds, respectively. The shape and trend of the stress
Residual Stress (MPa)

400 distribution are similar to the results of the SM400 welds.

300 Nonetheless, the longitudinal residual stresses near the weld
200 toe are larger at both locations. This is because the yield
100 stress of SM490 is larger than that of SM400. Namely,
0 welds undergo yielding in the process of cooling after
-100
welding; then tensile residual stresses over yield stress of
-200
the material remain there due to the resistance of the
0 50 100 150 200 250 material against contraction attributed to cooling after
Distance from the centreline (mm)
welding. Hence, residual stresses in welds increase with
Transverse Stress Profile (SM400) (b)
200
Depth_1.5mm
Depth_13.5mm Longitudinal Stress Profile (SM490) (a)
Residual Stress (MPa)

150
600
Depth_1.5mm

100 500 Depth_13.5mm

Residual Stress (MPa)

400
50 300

200
0
100

-50 0
0 50 100 150 200 250
-100
Distance from the centreline (mm)
-200
0 50 100 150 200 250
Through-thickness Stress Profile (SM400) (c) Distance from the centreline (mm)
100
Depth_1.5mm
Transverse Stress Profile (SM490) (b)
Depth_13.5mm
75 200
Depth_1.5mm
Residual Stress (MPa)

Depth_13.5mm
50
Residual Stress (MPa)

150

25
100
0
50
-25

0
-50
0 50 100 150 200 250
Distance from the centreline (mm) -50
Fig. 6 Residual stress profiles at a cross-section of the flange 0 50 100 150 200 250

perpendicular to the welding direction (SM400) Distance from the centreline (mm)

Through-thickness Stress Profile (SM490) (c)

100
Depth_1.5mm
stresses arise near the weld toe and level out in compression Depth_13.5mm
75
away from the weld toe for self-equilibrating purpose.
Residual Stress (MPa)

Moreover, the longitudinal residual stresses show through- 50

thickness variation. The variation is most likely due to the

25
steep temperature gradient experienced by the top-thickness
which is close to the heat source. The transverse residual 0

stresses are almost tensile and level out to zero. Like the -25
longitudinal residual stresses, the highest tensile transverse
-50
residual stresses arise near the weld toe and show through-
0 50 100 150 200 250
thickness variation. The normal stress components have Distance from the centreline (mm)
fluctuating profiles that vary between tensile and compres- Fig. 7 Residual stress profiles at a cross-section of the flange
sive and they also show through-thickness variation. perpendicular to the welding direction (SM490)
256 Int J Adv Manuf Technol (2009) 41:250–258

Longitudinal Stress Profile (SM520) (a) cooling after welding increases with increasing yield stress
600 of the material welded, the through-thickness contraction
Depth_1.5mm
500 Depth_13.5mm decreases, reversely.
Residual Stress (MPa)

400 The different simulated residual stress profiles for the

300 SM520 welds are shown in Fig. 8(a),(c). The residual
200 stresses follow similar trends where the tensile longitudinal
100 residual stresses are highest near the weld toe and gradually
0
level out in compression beyond the weld toe, transverse
-100
residual stresses are almost tensile and level out to zero
away from the centreline and the through-thickness residual
-200
0 50 100 150 200 250 stresses have fluctuating profiles. Through the careful
Distance from the centreline (mm)

Transverse Stress Profile (SM520) (b) (a)

Longitudinal Stress Profile (SM400)
200
Depth_1.5mm 700
Depth_1.5mm
Depth_13.5mm 600 Depth_8.0mm
Residual Stress (MPa)

150

Residual Stress (MPa)

500

100 400

300

50 200

100
0 0

-100
-50
-200
0 50 100 150 200 250
0 50 100 150 200 250 300 350 400 450 500 550 600
Distance from the centreline (mm)
Distance along the weld length (mm)

Through-thickness Stress Profile (SM520) (c)

Longitudinal Stress Profile (SM490) (b)
100
Depth_1.5mm 700
Depth_1.5mm
Depth_13.5mm
75 600 Depth_8.0mm
Residual Stress (MPa)

Residual Stress (MPa)

500
50
400

25 300

200
0
100

-25 0

-100
-50
0 50 100 150 200 250 -200
Distance from the centreline (mm) 0 50 100 150 200 250 300 350 400 450 500 550 600
Distance along the weld length (mm)
Fig. 8 Residual stress profiles at a cross-section of the flange
perpendicular to the welding direction (SM520)
Longitudinal Stress Profile (SM520) (c)
700
Depth_1.5mm
600 Depth_8.0mm
increasing yield stress of the material welded. Meanwhile,
Residual Stress (MPa)

500
the transverse residual stresses near the weld toe are larger 400
at the top-thickness while those at the bottom-thickness are 300
nearly unchangeable. This might be attributed to the slow 200
temperature gradient of transverse direction at the bottom- 100
thickness; therefore the contribution of yield stress to the 0
residual stress generation is small. On the contrary, the -100

through-thickness residual stresses near the weld toe are -200

0 50 100 150 200 250 300 350 400 450 500 550 600
smaller at both locations. This observation could be Distance along the weld length (mm)
explained by the phenomenon that since the longitudinal Fig. 9 Longitudinal residual stress profiles at the web weld toe along
and transverse resistance against contraction induced by the weld length (similar steels)
Int J Adv Manuf Technol (2009) 41:250–258 257

Stress Profile (TYPE1) (a) the results, it is known that the overall trend, shape and
600 Longitudinal magnitude of the residual stress profiles are similar to those
500 Transverse of the SM400 welds despite the slight difference between
Residual Stress (MPa)

Through-thickness
400 the residual stresses in parts at which the flange and web
300 come in contact with each other.
200 Figure 11 shows the longitudinal residual stress profiles
100 at the web weld toe (z=22) along the weld length. The
0
stress profiles are reported for depth at 1.5 mm from the top
-100
web surface. In the figure, it can also be shown that the
results are similar to those of the corresponding similar steel
-200
0 50 100 150 200 250 welds.
Distance from the centreline (mm)

Stress Profile (TYPE2) (b)

600 4 Conclusions
Longitudinal
500 Transverse
This study has clarified the characteristics of residual
Residual Stress (MPa)

Through-thickness
400
stresses in T-joint fillet welds made of similar and
300
dissimilar steels by employing three-dimensional uncoupled
200
thermal elastic-plastic FE analyses. Based on the results in
100
this work, we can draw the following conclusions:
0

-100
a) All the three residual stress components show through-
thickness variation. The variation is most likely due to
-200
0 50 100 150 200 250 the steep temperature gradient experienced by the top-
Distance from the centreline (mm) thickness which is close to the heat source.
Fig. 10 Residual stress profiles at a cross-section of the flange b) The maximum longitudinal residual stresses near the
perpendicular to the welding direction (dissimilar steels)
weld toe of the similar steel welds increase with
increasing yield stress of the steel welded.
c) For the dissimilar steel welds, the overall trend, shape
observations, it can be found that the longitudinal and
and magnitude of the residual stress profiles in flange
transverse residual stresses near the weld toe are the largest
and web are similar to those of the corresponding
while the through-thickness residual stresses near the weld
similar steel welds despite the slight difference
toe are the smallest among the three welds.
between the residual stresses in parts at which the
Figure 9 shows the longitudinal residual stress profiles at
flange and web come in contact with each other since
the web weld toe (z=22) along the weld length. Figure 9(a),
the material properties and mechanical constraints
(b) and (c) show the results for the SM400, SM490 and
applied of the flange and web are similar to those of
SM520 welds, respectively. The results are reported at two
the corresponding similar steel welds.
different depths at 1.5 mm (top-thickness) and 8.0 mm
(mid-thickness) from the top web surface. Here again, the
longitudinal residual stresses show through-thickness vari-
ation and increase with increasing yield stress of the steel
Longitudinal Stress Profile
welded. 700 TYPE1
Figure 10 shows the residual stress distributions at a 600 TYPE2
cross-section of the flange perpendicular to the welding
Residual Stress (MPa)

500
direction and half way through the weld length (x=300) 400
when welding dissimilar steels. The stress profiles are 300
reported for depth at 1.5 mm from the top flange surface. 200
The solid curve represents the longitudinal residual stress 100
profile, the dashed curve the transverse residual stress 0
profile, and the curve with long-dash and short-dash -100

the through-thickness (normal) residual stress profile. -200

0 50 100 150 200 250 300 350 400 450 500 550 600
Figure 10(a) and (b) show the results for the TYPE1 Distance along the weld length (mm)
(Flange: SM400, Web: SM490) and the TYPE2 (Flange: Fig. 11 Longitudinal residual stress profiles at the web weld toe along
SM400, Web: SM520) welds, respectively. According to the weld length (dissimilar steels)
258
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