RED-WeldS

“Finite element evaluation of distortions

in large welded assemblies”
Rapid Evaluation of Distortions
in Welded Structures

2 www.nafems.org
INDEX

1. Introduction
2. Methodology
3. Validation of the methodology
4. Application to industrial cases
5. Conclusions

3 www.nafems.org
Introduction Methodology Validation Application Conclusions

Nuclear
Naval

Welding
the main
Joining Technology
Equipment goods Defense

Automotive
Renewables 4 www.nafems.org
Introduction Methodology Validation Application Conclusions
PROBLEM
Out of tolerance

Additional processes

Time and costs increment

SOLUTION
Optimum welding sequence
&
Clamping location

DISTORTIONS ANALYSIS

5 www.nafems.org
Introduction Methodology Validation Application Conclusions

Thermo-mechanical-metallurgical models

Elastoplastic material behaviour f(T)

Viscous behaviour of molten zone
Phase transformations in HAZ
Computing time
Amount of data

Results:
• Distortions
• Residual stresses
• Hardening
• Phases

6 www.nafems.org
Introduction Methodology Validation Application Conclusions

Thermo-mechanical models

Elastoplastic material behaviour f(T)

Without metallurgical effects
Computing time
Amount of data

Results:
• Distortions
• Residual stresses (worst)

7 www.nafems.org
Introduction Methodology Validation Application Conclusions

Simplified mechanical models

Shrinkage Volume Approach

Minimum amount of data

Elastic material behaviour. NO f(T)
Linear elastic analysis
Non linearities due to:
• Geometry
• Constraints (contacts)

Results:
• Distortions
• Residual stresses (beyond HAZ)

8 www.nafems.org
Introduction Methodology Validation Application Conclusions

Simplified mechanical model

(Shrinkage Volume Approach)

9 www.nafems.org
Introduction Methodology Validation Application Conclusions
Wide experimental program (welding coupons and macrographs)
Different steel grades, thicknesses, welding joints and welding processes

S355 J2 N (20 mm) AISI 316L (4 mm)

FCAW GTAW

10 www.nafems.org
Introduction Methodology Validation Application Conclusions

Carbon steel coupon Stainless steel coupon

Base metal Filler metal Base metal Filler metal

S 355 J2 N E71T-1M AISI 316 L AISI 316 L

Density (kg/m3) 7850 7815 7966 7966

Elastic modulus (MPa) 210000 210000 192000 192000
Poissons’ ratio () 0.3 0.3 0.3 0.3
Thermal expansion coeff. (ºC-1) 1.6E-5 1.4E-5 1.6E-5 1.6E-5

11 www.nafems.org
Introduction Methodology Validation Application Conclusions

S355 J2 N
0
3 min

Workshop

2.01 2.76

5.57 4.77

6.99 6.41

12 www.nafems.org
Introduction Methodology Validation Application Conclusions

AISI 316 L
0
2 min

Workshop

8.66 7.27

14.69 14.69

13 www.nafems.org
Introduction Methodology Validation Application Conclusions
Pressure vessels. Nozzle to shell joints
N3A & N4A. Geometry

Coupon

14 www.nafems.org
Introduction Methodology Validation Application Conclusions
Pressure vessels. Nozzle to shell joints. N3A & N4A (Macrographs)

Bead 1 Bead 2 Bead 4

Bead 5

14
11 Bead 6
13 12 9
10 7
8
5
6
4
3
2
1

Bead 8
Bead 12

Bead 10 Bead 9

15 www.nafems.org
Introduction Nozzle N3A Methodology Validation Application Conclusions
Finite Element Model. Weld beads detail

Nozzle N4A

16 www.nafems.org
Introduction Position A Methodology Validation Application Conclusions
Boundary conditions

Position B

17 www.nafems.org
Introduction Methodology Validation Application Conclusions
After welding N3A After welding N4A
Distortions
Numerical results

Residual stresses

18 www.nafems.org
Introduction Methodology Validation Application Conclusions
Workshop measurement vs. numerical results (mm)

Pre-processing took 32 hours

2 welding operations
27 weld beads
163 min running
Nozzle N3A Nozzle N4A
WORK STATION
Measure Workshop Workshop Two processors Intel
measure measure XEON W5580 at 3.2 GHz
E -5 -4.5 -3 -4.4 24 GB of RAM
F 1 2.3 2 2.4
G -6 -4.5 -4 -4.4
L -7 -6.3 -3 -6.8
M -6 -6.3 -4 -6.8
N -1 -2.3 -2 -2.1

19 www.nafems.org
Introduction Methodology Validation Application Conclusions
Reinforced saddle

Geometry

Ø = 5.5 m

20 www.nafems.org
Introduction Methodology Validation Application Conclusions
Coupons & Macrographs

Side with edge preparation

Side with edge preparation

Side with no edge preparation
Weld bead #1

Side with no edge preparation

Weld bead #2

Side with no edge preparation Side with no edge preparation

Weld bead #3
21 www.nafems.org
Introduction Methodology Validation Application Conclusions
Modeling. Bead details

22 www.nafems.org
Introduction Methodology Validation Application Conclusions
Results

Distortions
126 welding operations
1261 weld beads
10 min / bead
9 days running

Residual stresses

23 www.nafems.org
Introduction Methodology Validation Application Conclusions

Workshop measurement vs. numerical results Measure # 4

Initial Final Workshop

Measure 1 (mm) 404 404 0 1.6

Measure 2 (mm) 406 407 1 1.8

Measure 3 (mm) 415 415 0 0.0

Measure 4 (mm) 5513 5474 -39 -33.3

Measure # 1 Measure # 5 Measure # 3 Measure # 6 Measure # 2

Measure 5 (mm) 1419 1414 -5 -4.3

Measure 6 (mm) 1413 1417 4 3.4

Measure A (mm) 1229 1227 -2 -1.9

Measure B (mm) 1220 1218 -2 -1.8

Measure C (mm) 956 954 -2 -2.4

Measure D (mm) 945 944 -1 -1.7

Measure # A Measure # C Measure # D Measure # B

24 www.nafems.org
Introduction Methodology Validation Application Conclusions

&
 Minimal amount of data. Materials properties at Troom.

 Thermal analysis  Not necessary.

 RED-WeldS, vertical tool for ANSYS®, allows the distortion prediction due to
the welding process in large assemblies.

 Useful for determining the optimum welding sequence and/or the clampling
location.

25 www.nafems.org
 “Rapid Evaluation
of Distortions
in Welded Structures”

Tool implemented in AANSYSS

to predict welding distortion in
large welded structures
in a fast and accurate way

26 www.nafems.org
 Engineering Area

Thank you for your attention

Contacto: M. Armindo Guerrero Julio Jorge

Engineering Manager Head of Engineering Area
m.armindo@itma.es j.jorge@itma.es

H PEPA C/ Calafates, 11 (Parcela L.3.4) 33417 Avilés – Asturias (Spain)

' Tfno.: +34 985 129 120
7 Fax: +34 985 129 008

27 www.nafems.org