Three-dimensional finite element simulation of residual stresses in circumferential welds of steel pipe including pipe diameter effects

In circumferential welding of a pipe component, it is often considered that axisymmetric model can provide a reasonable prediction of the residual stress distributions. However, in general, the axisymmetric model cannot reproduce the traveling arc along circumferential welds and rapid change of residual stresses that can be observed in the overlapping region. Moreover, it tends to overestimate the hoop residual stresses in circumferential welds. Therefore, three-dimensional finite element (FE) model is essential for the accurate simulation of circumferential welding which can incorporate the three-dimensional effects. This paper presents the three-dimensional FE simulation of circumferential butt welding of a steel pipe. The thermo-mechanical model used as well as the simulation methodology is detailed, and the results are discussed. In addition, parametric studies with inside radius to wall thickness ratio ranging from 10.0 to 100.0 have been presented to investigate the effects of pipe diameter on residual stresses. Axial and hoop residual stresses are plotted for the considered range of pipe diameters, and the differences are discussed.