Numerical and experimental investigations on the residual stresses of the butt-welded joints

Welding is a reliable and efficient joining process in which the coalescence of metals is achieved by fusion. Localized heating during welding, followed by rapid cooling, can generate residual stresses in the weld and in the base metal. Estimating the magnitude and distribution of welding residual stresses is important. This study applies thermal elasto-plastic analysis, using finite element techniques, to analyze the thermomechanical behavior and evaluate the residual stresses in butt-welded joints. The residual stresses at the surface of the weldments were measured by X-ray diffraction. The results of finite element analysis were compared with experimental residual stress data to confirm the accuracy of the method. The aim is to present data that may confirm the validity of currently employed fabrication processes in welded structures and even improve them.