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SIMULATION OF TIG WELDING
PROCESSS

Prof.(Dr.) P. RAVINDER REDDY

Professor and Head, Mechanical Engineering Department
Chaitanya Bharathi Institute of Technology(A)
(Affiliated to Osmania University) Gandipet, C.B.Post, Hyderabad-500075

1
 PREFACE

During the course of the welding, high residual stress and distortion often occur. This
causes the problem in nuclear power plant components especially where the danger of
stress corrosion cracking (SCC) exists. In this study, both the experimental and the finite
element methods (FEM) are utilized to investigate the welding residual stress distribution
in medium thick-walled austenitic stainless steel plates

TIG welding is one of the important weld process required for the fusion reactor
components development and fabrication. The major components developed for usage for
the construction utilize various grades of stainless steel like SS 304, SS316, SS 316L and
some nuclear grade special materials with various thicknesses ranging from 5 mm to
60mm. The joining and welding of the materials has major impact on the life of tokomak
structures as they undergo various stringent conditions like thermal, mechanical and
nuclear radiation effects. Hence every sub system has to be carefully fabricated with the
recommended process and material properties as per required. The major methods for
proposed components are TIG welding, Laser welding, Electron Beam Welding and
Hybrid TIG laser welding. The present of work is aimed at the TIG process parameters
selection and optimization with focus on weld sample output quality parameters namely
temperature distribution, residual stresses, weld distortion.

A 10 mm thick SS 316 plate of dimensions 300x150mm with TIG welding is selected as

experimental investigation and combination of FEM analysis using ANSYS software to
predict the temperature variation and thermal stresses with varying plate thickness,
voltage and efficiency factor.

The chapter two contains the literature review in the welding domain and its literature
survey. The chapters three and four deal with the details of the welding process and the
welding process employed with the description of the process. The chapter five is a brief
description of the FEM and introduction to ANSYS and the steps involved in the process

2
of computation using ANSYS. The chapter six is the detailed work review of the work
done in ANSYS. The chapter seven is results and discussions held during the project
course of time and its results. Chapter eight deals with the conclusions drawn from the
present work and future scope of work in the field of welding process.

3
 CONTENTS

Abstract 2-3

Chapter Description Page No

1 INTRODUCTION 7

2 LITERATURE REVIEW 8-12

2.1 About TIG welding simulation 8

2.2 Residual Stresses in welding 10

3 WELDING OVERVIEW 13-20

3.1 Welding Technology 13

3.2 Classification of welding processes 13
3.3 Flow Chart for Welding Process 15
3.4 Development of Welding Technology 15
3.5 Benefits & Threats of Welding 16
3.6 Weld Induced Residual Stresses 17

4 TIG WELDING PROCESS 21-33

4.1 Introduction 21
4.2 TIG welding and Various Input parameters Used 21
4.3 TIG Welding 21
4.4 Process Characteristics 22
4.5 Power Source 23
4.6 Arc Starting 23
4.7 Electrodes 24
4.8 Shielding Gas 24
4.9 TIG Welding Benefits 25
4.10 Applications 25
4.11 Electrode 25

4
 4.1 2 Shielding Gas 26
4.13 Commercial TIG Torches 26
4.14 Check List 26
4.15 TIG-Automatic Torch 27
4.16 Check List 27
4.17 TIG Weld Joints 27
4.18 Safety Precautions 30
4.19 Experiment Details 31
4.20 Experimental Results 32
4.21 Weld Experiment Data 33

5 FINITE ELEMENT METHOD 34-49

5.1Historical Background 35
5.2 Need For Finite Element Method 35
5.3 The Process Of Finite Element Method 35
5.4 Field And Boundary Conditions 36
5.5 Steps Involved In Finite Element Modeling 36
5.6 Applications Of Finite Element Method 37
5.7 Fea Software – ANSYS 39
5.8 Procedure For ANSYS Analysis 41
5.9 Solutions 46
5.10 Structural Static Analysis 47
5.11 Post processor 48
5.12 Residual Stresses 48
5.13 Sources of residual stresses 49
5.14 Effects of Various Factors on Residual Stresses 49
5.15 Development of Welding Residual Stresses 49

5
6 MODELING OF TIG WELDING USING FEA 50-64

6.1 Modeling 50
6.2 Problem Definition 52
6.3 Material Used 52
6.4 Material Properties 53
6.5 Element Description 54
6.6 Thermal Loading 59
6.7Boundary Conditions 60
6.8Heat Transfer Analysis 61
6.9Mechanical Analysis 62
6.10 Input Calculations 63
6.11Calculation of Heat Flux (q) 63
6.12Thermal and structural analysis of 63
welded workpiece using FEA

7 RESULTS AND DISCUSSIONS 65-82

7.1 Thermal Results 66

7.2 Temperature variation by varying weld parameters 70
7.3 Structural Results 80

8 CONCLUSIONS AND FUTURE SCOPE OF WORK 83-84

REFERENCES 85-86

6
 Chapter 1
INTRODUCTION

The Stainless steel 316 (SS 316) plate of dimension 300 mm X 150 mm X 10 mm has
been used as a work piece material for present experiment study. And ER 316L weld rods
are used as filler materials for the weld joining process. A model was generated in
ANSYS (A general purpose FEA software) using SOLID BRICK 8 NODE 70 (3D solid
element with temperature dof) and PLANE 55 (A 2D Solid Element with 4 nodes), as per
the dimensions of the plate taken for the experimentation. A refined mesh is made based
on the convergency criteria and the analysis is performed to estimate the temperature
distribution. Firstly a transient thermal analysis was carried out by giving heat flux as the
time varying input to estimate the temperature variation. The non-linear material
properties are fed for the heat transfer solution. Then coupled field analysis is carried out
to get the residual stresses and distortion by coupling thermal analysis to static analysis.
The variation of the temperature with time, the residual stresses and distortion are
obtained. The variation of these are reported and discussed.

7
 Chapter 2
LITERATURE REVIEW

In recent years, with the development of powerful computing facilities, Finite

Element (FE) analysis methods have been applied to the simulation of TIG welding using
commercial FE software packages.

2.1 About TIG welding simulation

The research activity in welding simulation started decades ago. Rosenthal [1],
(1946) was among the first researchers to develop an analytical solution of heat flow
during welding based on conduction heat transfer for predicting the shape of the weld
pool for two and three-dimensional welds. Using the Fourier partial differential equation
(PDE) of heat conduction, he introduced the moving coordinate system to develop
solutions for the point and line heat sources and applied this successfully to address a
wide range of welding problems. His analytical solutions of the heat flow made possible
for the first time the analysis of the process from a consideration of the welding
parameters namely the current, voltage, welding speed, and weld geometry.
Understanding of the theory of heat flow is essential in order to study the welding
process analytically, numerically or experimentally. Since the pioneering work of
Rosenthal, considerable interest in the thermal aspects of welding was expressed by many
researchers such as Kamala and Goldak [2], (1993), Nguyen et al. [3], (1999), and
Komanduri and Hou [4], (2000).
The most critical input data required for welding thermal analysis are the
parameters necessary to describe the heat input to the weldment. Goldak et al. (1984)
derived a mathematical model for welding heat sources based on a Gaussian distribution
of power density. They proposed a doubled ellipsoidal distribution in order to capture the
size and shape of the heat source of shallow and deeper penetrations. Some researchers
have also developed the thermal finite element simulation to investigate the temperature

8
distribution of a metal such as Kraus (1986), Tekriwal and Muzumder (1988), Yeung,
and Thorthon (1999), and Bonifaz (2000).
Over the past few years, finite element methods have been used extensively in an
attempt to predict distortion and residual stresses due to welding operations such as the
studies by Friedman [5], (1975), Brown and Song [6], (1992), Mechaleris and Debiccari
(1997), Frewin and Scott [7], (1999), and Taylor et al. (1999). Generally, the finite
element method has already been proven to be a successful tool to simulate the complex
welding process as performed by Friedman (1975). His 2-D finite element analysis work
was then used by Taylor et al. [8], (1999) to verify their 3-D computational modeling of
welding phenomena. The results of finite element analysis done by Taylor et al. (1999)
were in reasonable agreement with the result obtained by Friedman (1975). The
Freidman’s work has also been used in this thesis as a verification finite element model.
Most of the welding research in the past was conducted to investigate the
distribution of residual stress and distortion of welded metal. The work performed by
Mandal and Sundar (1997) for example, estimates the welding shrinkage in a welded butt
joint by applying a mathematical model approach. Michaleris and Debiccari, and
Okumoto [9], (1997,1998) conducted thermo-elasto-plastic finite element analysis for
welding simulation to predict the welding distortion. They have claimed that their
approaches have been proven consistent to experimental and empirical data. Furthermore,
Puchaicela (1998) in his article reviewed and analyzed several formulas and figures in an
attempt to provide a practical guide for the control and reduction of distortion.
Not only the welding residual stress and distortion have been studied by welding
researchers, but the effects of welding parameter, welding sequence, welding joint
geometry, and root opening has also been investigated by several researchers in the past.
Harwig et al. (1999) for instance, studied the effect of welding parameters and electrode
classification on the diffusible hydrogen content of gas shielded flux cored arc welds. In
1999, Tsai et al. studied the effect of welding sequence on buckling and warping behavior
of a thin-plate panel structure. Tsai et al. (2001) have also investigated the effects of
welding parameters and joint geometry on the magnitude and distribution of residual
stresses on thick-section butt joints. The effect of the root opening on mechanical
properties, deformation and residual stress has been reported by Jang et al. (2001)

9
 As shown by the above researchers, residual stress distribution and distortion in a
welded plate are strongly affected by many parameters and by their interaction. Yet,
certain aspects of the welding phenomenon are still subject to further research
specifically the effects of heat input, welding speed responses as applied to steel plate
welding.
Asibu et al [10], (1989), determined the mechanical properties and load carrying
capacity of the weldment by using the temperature and associated cooling rates that arise
during welding. Numerical methods had been used for weld pool for higher accuracy.
Krutz and Segerlind [11], (1981), determined the time-temperature relationships
throughout the structure in the welded joints using finite element method. He had
reported that, the transient thermal flow affected the metallurgy in the heat affected zone,
by varying certain welding parameters, the weld joint strength could be optimized when a
certain metallurgical view point. The problems of distortion and reduced strength of the
material in the joint area were the results of the large amount of heat energy applied at the
weld site over a short period of time. The authors had reported that heat gradient at
elevated temperatures caused dynamic changes in the weld metallurgy, which affected
the joint strength.
L.E.Lindgren, et. al.,[12]. (1987), Developed the Finite Element Techniques for
Facilitating the Simulation of Welding in Industrial Applications .This paper summarized
some of the developments that had been done in order to facilitate the simulations in
some of the research projects at the division.

2.2 Residual stresses in welding

Residual Stresses are those stresses that would exist in a body if all external loads
and restraints were removed. Various technical terms have been used to refer the residual
stresses, such as internal stress, Initial stress, inherent stress, reaction stress and locked-
in stresses. Residual stresses in metallic components may occur for many reasons such as
rolling, casting and forging of plates and bars, forming and shaping of metal parts by
such processes as shearing, bending, machining, grinding and welding.
Welding residual stresses are generated in a structure as a consequence of local
plastic deformations introduced by local temperature history consisting of a rapid heating

10
and subsequent cooling phase. During the welding process, the weld area is heated up
sharply compare to the surrounding area and fused locally. The material expands as a
result of being heated. The thermal expansion of the material is restrained by the
surrounding cooler area, which gives rise to thermal stresses. The thermal stresses are
partly exceeds the yield limit, which is lowered at elevated temperatures. Consequently,
the weld area is plastically hot-compressed. After cooling down too short, too narrow or
too small comparing to the surrounding area, it develops tensile residual stress, while the
surrounding areas are subjected to compressive residual stresses to maintain the self-
equilibrium D. Radaj [13], 1992).
Thermo-mechanical history measurement of welding process is essential but
proves to be prohibitively expensive and time consuming. It often fails to provide a
complete picture of temperature and strain/deformation distribution in the weldment. On
the other hand, detailed experimental measurements of the residual elastic strain
distributions in welded parts are typically not feasible from a manufacturing standpoint.
Mathematical modeling for residual stress evaluation proves to be a more
effective way than experimental methods. However development of the modeling scheme
requires a solid experimental basis. Many stress analyses have been carried out to
understand the residual stress distributions induced by welding processes analytically and
numerically. The type of model used and the sophistication of the analysis has often
hinged on the accuracy required and the type of computational resource available to solve
the problem. Most of the residual stress studies were conducted based on either
axisymmetric or 2D plane assumptions.
In the simplified analytical method, it is assumed that the welding residual
stresses are determined by the local plastic shrinkage strains generated during cooling
after welding. Hence, although the weldment undergoes many complex physical changes,
involving interactions between micro structural, thermal and mechanical changes during
welding processes, the plastic strains accumulated during the final stages of cooling
largely determine the residual distortion. Vaidyanathan [14], 1973, evaluated residual
stress in piping components by imposing on a cylinder the residual stress profile
generated by a similar weld in a plate through using thin shell theory. The applicability of
this technique is limited to thin-walled pipes with one weld pass.

11
 B. Taljat et. al., [15], 1998, analyzed numerically the residual stress distribution in
spiral cladded tubes. Authors had developed the axisymmetric FE model to simulate the
circumferential weld cladding process and analyzed the residual stress strain rate. The
analysis was uncoupled in that the thermal and mechanical analyses were conducted in
two separate runs. The results showed high tensile residual stresses in the weld cladding
and at the interface with gradual residual stresses at the inner tube surface.
The finite element modeling and simulation of welding has been extensively
reviewed by Lindgren [16], 2001. He discussed the different aspects of finite element
simulation of welding and also explained advantages and disadvantages of different
techniques. Simulations where two-dimensional models are used still dominate the
published work. This is partly due to the fact that they give useful results and partly due
to the fact that three-dimensional simulations demand a large computing power if a good
resolution is to be obtained. Michaleries and Debiccari [9], 1997, transferred welding
residual stresses obtained from a 2-D plane deformation model to a 3-D model of the
structure in order to study weld-induced buckling. The first 3-D residual stress prediction
of full weld appear to be by Lindgren and Karlsson [17], 1988, who used shell elements
when modeling a thin-walled pipe. Karlsson and Josefson [18], 1990, modelled the same
pipe using solid elements. The results from the different models were consistent.
Nasstrom et al. [19], 1992, made a first attempt to combine shell and solid elements in the
modeling of welding.

12
 Chapter 3

WELDING OVERVIEW

Welding is a materials joining process which produces coalescence of materials by

heating them to suitable temperatures with or without the application of pressure or by
the application of pressure alone, and with or without the use of filler material. Welding
is used for making permanent joints. It is used in the manufacture of automobile bodies,
aircraft frames, railway wagons, machine frames, structural works, tanks, furniture,
boilers, general repair work and ship building.

3.1 Welding Technology

Welding technology is a major part of any mechanical manufacturing facility in the

world. It is considered as the most wide-spread metal joining process in the
industries.
Generally, welding can be defined as any process in which two or more pieces of metal
are joined together by the application of heat, pressure, or a combination of both. Most
of the welding processes may be grouped into two main categories :

(1) Pressure Welding. The welding in which the weld is achieved by applying the
pressure.
(2) Heat Welding. The welding in which the weld is achieved by the function of
heat. Today, the heat welding is the most common welding type used in the
industries.

3.2 Classification of welding processes

(1) Arc welding

• Carbon arc
• Metal arc
• Metal inert gas

13
 • Tungsten inert gas
• Plasma arc
• Submerged arc
• Electro-slag
(2) Gas Welding
• Oxy-acetylene
• Air-acetylene
• Oxy-hydrogen
(3) Resistance Welding
• Butt
• Spot
• Seam
• Projection
• Percussion
(4) Thermit Welding

(5) Solid State Welding

• Friction

• Ultrasonic

• Diffusion

• Explosive

(6) Newer Welding

• Electron-beam

• Laser

14
3.3 Flow Chart for Welding Process

3.4 Development of Welding Technology

The earliest welding technology has been traced as back as 1000 BC when the
forge welding had been utilized into weapons. First time the use of electric fusion process
has been reported in 1782 in Germany by G. Lichtenberg . However, the most of the
references show commencement of electric arc welding process in late nineteenth
century.
A brief summary of the development in welding processes is given below:

1801: Discovery of electric arc by Sir Humphrey Devy

15
1860-1865 : Wilde first intentionally joined metal by electric welding in early 1860 and
was granted a patent in 1865 for his work

1885 : De Meritens obtained patent of electric arc welding process in England using
carbon electrode
1886 : E. Thomson obtained a patent on resistance
1887 : Benardos, a Russian scientist, got first patent of electric arc welding for
slightly different equipment then by De Meritens
1891: Another Russian N. Slavianoff replaced carbon electrode with a metal electrode
and obtained a patent on metal arc welding
1908-1940 : Kjellberg, a Swedish, got a patent for coated welding electrode
Development in joining process continued and major welding process including
oxyacetylene, MMAW (manual metal arc welding), GTAW (gas tungsten arc welding),
and GMAW (gas metal arc welding) processes were successfully implemented
1960 : Advanced welding types such as Electron Beam, Laser and Ultrasonic welding
were developed during 1950-1960
2000 : Most recent development is magnetic pulse welding introduced

3.5 Benefits & Threats of Welding

Welding represents one of the most complex manufacturing processes in terms of

number of variables involved and factors contributing to the final output or
response.
Welding has been used in the fabrication of structures ranging from conventional
industrial applications to high-tech engineering applications in aeronautical nuclear,
aerospace, marine and high-pressure vessel applications. Compared to mechanical
joining methods, welding method offers some significant advantages including
flexibility of design, improved structural integrity and weight & cost savings . However,
the welding method induces the thermal strains in the weld metal and base metal
regions near the weld, resulting in stresses, which in turn combine and react to
produce internal forces that cause bending, buckling, and rotation. These

16
displacements are known as welding distortions . As a widely used mechanical
manufacturing technique, welding offers a number of technical challenges to the
welding community specially shop floor engineers engaged in manufacturing of
different welded structures. While joining the components of a structure together by
welding, the complex thermal cycles from welding result in formation of residual stresses
in the joint region, and deformation of the welded structure. Both weld residual
stresses and distortions can significantly impair the performance and reliability of the
welded structures . They must be properly dealt with during the product and process
design and manufacturing phases, to ensure intended in-service use of the welded
structures. Despite the recognition of welding as one of the most important fabrication
processes in the engineering industries, there is a little scientific understanding present in
the productivity measurement and evaluation of the welding processes.

3.6 Weld Induced Residual Stresses

Residual stresses are those stresses that would exist in a body if all external loads
and restraints were removed. Various technical terms have been used to refer to
residual stress, such as internal stress, initial stress, inherent stress, reaction stress and
locked-in stress . Mechanical structures suffer from residual stresses during different
phases of their life cycle. In engineering structures most of the residual stresses are
induced during their manufacturing phase including casting and forging, sheet metal
forming and shaping (shearing, bending, grinding, machining etc.) and welding.

Welding residual stresses are produced in a structure as a consequence of local

plastic deformations introduced by local temperature history consisting of a rapid
heating and subsequent cooling phase. During the welding process, the weld area is
heated up sharply compare to the surrounding area and fused locally. The material
expands as a result of being heated . The heat expansion is restrained by the surrounding
cooler area, which gives rise to thermal stresses. The thermal stresses partly exceed
the yield limit, which is lowered at elevated temperatures. Consequently, the weld
area is plastically hot-compressed. After cooling down too short, too narrow or too

17
small comparing to the surrounding area, it develops tensile residual stress, while
the surrounding areas are subjected to compressive residual stresses to maintain the
self-equilibrium .
Figure 3.1, shows the calculated longitudinal and transverse residual stresses in center
cross sections of rectangular plate at centre of weld. Due to the heating and cooling
cycles and constraints from surrounding materials, high longitudinal stress is
developed at central section of the plate. As the distance from the weld center
increase, the longitudinal stress gradually decreases. Along the transverse direction,
the longitudinal stress changes to compressive, whereas along the longitudinal
direction it reduces to zero, as dictated by the equilibrium condition of residual
stresses. Similar transverse residual stress with minor differences in distribution from
the longitudinal stress and smaller magnitude is observed.

Fig 3.1 Schematic view of residual stresses in welded rectangular plate

18
Welding induced distortion can be defined as change in shape and dimension of a
welded plate, after welding when the structure is free from any of the external forces of
thermal gradients. The interaction of solidifying weld metal with the parent base
metal, results in change in dimensions and shape of the weldments, generally
referred to as welding distortions. Different types of distortion patterns for plate
welding as presented in Figure 3.2. Further, in recent years many researchers presented
mechanism involved and the factors affecting different types of welding distortions.
The temperature distribution is not uniform due to the locally heating of material during
welding process. The stresses are released in the melted weld pool and can be assumed
to zero. The metal starts to shrink during the solidification of the melted weld pool and to
exert stresses on the surrounding weld metal and HAZ. These stresses remain in the
material after welding and result in unwanted distortion. A typical example of distortion
is given in Figure 3.2.

The three different types of residual stress induced distortion can be found in
manufactured structures as shown in Figure 3.1.The longitudinal and transverse
shrinkage can cause in plane distortion of the work piece whereas plane or
axisymmetrical angular shrinkage can cause distortion perpendicular to the plane of
the welded component and another distortion is bending due to grids with longitudinal
and transverse welds .

The residual stresses and the structure deformations are highly affected by the using of
welding fixtures during welding process and the amount of restraint determines the
control of distortions and residual stress fields on the weldments . Generally,
welding residual stresses and strains behave in opposing ways with degree of restraint as
shown in Figure 3.3. Therefore, the type of weld fixtures is used that keep residual
stresses low, and those, which reduce residual distortions.

19
 Fig 3.2 Example of distortion that can occur during welding

Fig 3.3 Effect of the degree of clamping on the level of distortion & residual stresses

20
 Chapter 4
TIG WELDING PROCESS

4.1 Introduction
In the construction of pressure vessels and storage tanks, the weld ability play unique
role in selection of materials from the various other materials. In the domain of joining
processes of Stainless steel and its alloys, the tungsten inert gas (TIG) welding process
continues its apex position due to its versatility and flexibility in adaptation. The superior
weld quality obtained in TIG weldments differentiates the TIG process in comparison
with other competing and emerging joining processes. Even after decades of its
inventions, TIG process continued in its marathon race even in fusion reactor field where
the quality and reliability are vital factors due its inherent advantages. Stainless steel
fabrication is preferred when compared to other materials fabrication. Since its offers a
considerable mass advantage to the extent of as high as 40 % to existing materials. In
addition, repair procedures and methodology are easily to be adopted and hence it is
highly recommended for fusion reactor applications.

4.2 TIG welding and Various Input parameters Used

Welding is the process of joining two pieces of metal by creating a strong metallurgical
bond between them by heating or pressure or both. It is distinguished from other forms of
mechanical connections, such as riveting or bolting, which are formed by friction or
mechanical interlocking. It is one of the oldest and reliable methods of joining.

4.3 TIG Welding

Tungsten inert gas (TIG) welding became an overnight success in the 1940’s for
joining magnesium and aluminum. Using an inert gas shield instead of a slag to protect
the weld pool, the process was a highly attractive replacement for gas and manual metal
arc welding.TIG has played a major role in the acceptance of aluminum for high quality
welding and structural applications.

21
4.4 Process Characteristics
In the TIG process the arc is formed between a pointed tungsten electrode and the
work piece in an inert atmosphere of argon or helium. The small intense arc provided by
the pointed electrode is ideal for high quality and precision welding. Because the
electrode is not consumed during welding, the welder does not have to balance the heat
input from the arc as the metal is deposited from the melting electrode. When filler metal
is required, it must be added separately to the weld pool.

Fig 4.1 TIG welding

Fig 4.2 Welding process diagram

22
4.5 Power Source

TIG must be operated with a drooping, constant current power source – either DC
or AC. A constant current power source is essential to avoid excessively high currents
being drawn when the electrode is short – circuited on to the work piece surface. This
could happen either deliberately during arc starting or inadvertently during welding. If, as
in MIG welding, a flat characteristic power source is used, any contact with the work
piece surface would damage the electrode tip or fuse the electrode to the work piece
surface. In DC, because arc heat is distributed approximately one-third at the cathode
(negative) and two-third at the anode (positive), the electrode is always negative polarity
to prevent overheating and melting. However, the alternative power source connection of
DC electrode positive polarity has the advantage in that when the cathode is on the work
piece, the surface is cleaned of oxide contamination. For this reason, AC is used when
welding materials with a tenacious surface oxide film, such as aluminum.

4.6 Arc Starting

The welding arc can be started by scratching the surface, forming a short-circuit. It is
only when the short-circuit is broken that the main welding current will flow. However,
there is a risk that the electrode may stick to the surface and cause a tungsten inclusion in
the weld. This risk can be minimized using the “lift arc” technique where the short-circuit
is formed at a very low current level. The most common way of starting the TIG arc is to
use HF (high frequency). HF consists of high voltage sparks of several thousand volts,
which last for a few microseconds. The HF sparks will cause the electrode-work piece
gap to break down or ionize. Once an electron /ion cloud is formed, current can flow
from the power source.
Note: As HF generates abnormally high electromagnetic emission (EM), welders
should be aware that its use can cause interference especially in electronic equipment. As
EM emission can be airborne, like radio waves, or transmitted along power cables, care
must be taken to avoid interference with control systems and instruments in the vicinity
of welding.

23
 HF is also important in stabilizing the AC arc; in AC, electrode polarity is reversed
at a frequency of about 50 times for second, causing the arc to be extinguished at each
polarity change. To ensure that the arc is reunited at each reversal of polarity, HF sparks
are generated across the electrode/work piece gap to coincide with the beginning of each
half-cycle.

4.7 Electrodes
Electrodes for DC welding are normally pure tungsten with 1 to 4% thorium to
improve arc ignition. Alternative additives are lanthanum oxide and cerium oxide, which
are claimed to give superior performance (arc starting and lower electrode consumption).
It is important to select the correct electrode diameter and tip angle for the level of
welding current. As a rule, the lower the current the smaller the electrode diameter and
tip angle. In AC welding, as the electrode will be operating at a much higher temperature,
tungsten with a zircon addition is used to reduce electrode erosion. It should be noted that
because of the large amount of heat generated at the electrode, it is difficult to maintain a
pointed tip and the end of the electrode assumes a spherical or “ball” profile.

4.8 Shielding Gas

Shielding gas is selected according to the material being welded. The following guide
lines may help:
• Argon - the most commonly used shielding gas, which can be used for welding
a wide range of materials including steels, stainless steel, aluminum and titanium.
• Argon - 2 to 5% 112-the addition of hydrogen to argon will make the gas slightly
reducing, assisting the production of cleaner-looking welds without surface
oxidation. As the arc is hotter and more constricted, it permits higher welding
speeds. Disadvantages include risk of hydrogen cracking in carbon steels and
weld metal porosity in aluminum alloys.
• Helium and helium/argon mixtures - adding helium to argon will raise the
temperature of the arc. This promotes higher welding speeds and deeper weld

24
 penetration. Disadvantages of using helium/argon mixture are the high cost of gas
and difficulty in starting the arc.

4.9 TIG Welding Benefits

• Superior quality welds.

• Welds can be made with or without filler metal.
• Precise control of welding variables(heat).
• Free from spatter.
• Low distortion.

4.10 Applications

TIG is applied in all industrial sectors but is especially suitable for high quality
welding. In manual welding, the relatively small arc is ideal for thin sheet material or
controlled penetration (in the root run of pipe welds). Because deposition rate can be
quite low (using a separate filler rod) MMA or MIG may be preferable for thicker
material and for fill passes in thick-wall pipe welds.
TIG is also widely applied in mechanized systems either autogenously or with filler wire.
However, several “off the shelf” systems are available for orbital welding of pipes, used
in the manufacture of chemical plant or boilers. The systems require no manipulative skill,
weld pool behavior, careful attention must be paid to edge preparation (machined rather
than hand-prepared), joint fit-up and control of welding parameters.

4.11 Electrode
The water-cooled GTAW torches necessarily involve the flow of cold water though
the copper nozzles so that the water takes away the heat generated due to the hot
electrode. When the arc is struck between the electrode and work piece, the temperature
attained by the work piece is around 2500 deg C. at that temperature tungsten; copper and
the body would just melt away. As a result a water-cooling is necessitated apart from
argon flow. The inlet water comes in a coaxial tube housing the electrical cable and the

25
return hot water flows separately. There is a pipeline for the argon gas to flow away from
ceramic nozzle there by protecting the weld bead.

4.12 Shielding Gas

The flow of argon is controlled using solenoid valves, which are electrically, and
PLC controlled. As soon as the arc is struck the argon starts flowing continuously at the
rating pressure subsequently to which the weld bead takes place. Apart from this, when
the arc is stopped, the argon continuous to flow for another 5 to 10 seconds depending on
the severity of the weld. This ensures the production of the hot bead of the weld. There is
a phase lag between the flow up argon to the regular argon. The back up argon is
provided by the thickness of component. If the thickness of the component is below 3mm
on the welding heat is lightly to get the part oxidized underneath the weld bead and the
component then is mandatory to provide additional.

4.13 Commercial TIG Torches

Gas cooled TIG torches for welding C-steel, special steel and aluminum is apparatus ,
container and pipe line construction.
4.14 Check List
Continuous current adjustment with UP/DOWN button.
Easy to use rocker switch.
Highly effective cooling of torch body.
Flexible torch body on request.
60 deg Rotatable torch.
Rotatable protective hose with highly flexible corrugated hose.
Ergonomic handle.
S-version with comfortable gas shutoff valve.
Plug - type gas nozzle.
Large assortment of gas nozzle.

26
4.15 TIG-Automatic Torch
Gas cooled TIG-automatic torch.

4.16 Check List

Highly effective cooling of torch body.
Customer individual solutions possible.
Temperature and ozone resistant rubber hose.
Plug type (AL) or thread type (PL) gas nozzle system.

4.17 TIG Weld Joints

The most common TIG welds are illustrated below. They include the:

• butt joint,
• lap joint,
• T-joint, and
• Fillet weld.

Fig 4.3 TIG weld joints

1) LAP Joint

Hold the torch 70 degrees to the work.To produce the best results, hold a short arc, travel
at a uniform speed, and feed the electrode downward at a constant rate as it melts. After
learning to start and hold an arc, practice running beads of weld metal on flat plates using
a full electrode.Hold the electrode nearly perpendicular to the work, although tilting it
ahead (in the direction of travel) will be helpful. To produce the best results, hold a short
arc, travel at a uniform speed, and feed the electrode downward at a constant rate as it
melts.

27
 Fig4.4 Torch position for welding lap joint

2) T-Joint

Hold the torch 70 degrees to the work. To produce the best results, hold a short arc, travel
at a uniform speed, and feed the electrode downward at a constant rate as it melts.

Fig4.5 Torch position for welding T-joint

28
3) CORNER Joint

Hold the torch 70 degrees to the work. To produce the best results, hold a short arc, travel
at a uniform speed, and feed the electrode downward at a constant rate as it melts

Fig4.6 Torch position for welding corner joint

4) BUTT Joint

Hold the torch 75 or 60 degrees to the work. To produce the best results, hold a short arc,
travel at a uniform speed, and feed the electrode downward at a constant rate as it melts

Fig4.7 Butt joint

29
4.18 Safety Precautions

1. Check the welding machine to make sure that it is properly grounded and that all
leads are properly insulated.
2. Never look at the arc with the naked eye. The arc can burn your eye severely
always use face shield while welding.
3. Prevent welding cable from coming in contact with hot metal, water, oil or grease.
Avoid dragging the cables around sharp corners.
4. Ensure proper insulation of the cables and check for openings.
5. Always near the safety hand gloves, apron and leather shoes.
6. Always turn off the machine when leaving the work.
7. Apply eye drops after welding is over for the day, to relieve the strain on the eyes.
8. While welding, stand on dry footing and keep the body insulated from the
electrode and any bare parts of the electrode holder and the work.
9. Check the welding machine to make sure that it is properly grounded and that all
leads are properly insulated.
10. Never look at the arc with the naked eye. The arc can burn your eye severely
always use face shield while welding.
11. Prevent welding cable from coming in contact with hot metal, water, oil or grease.
Avoid dragging the cables around sharp corners.
12. Ensure proper insulation of the cables and check for openings.
13. Always near the safety hand gloves, apron and leather shoes.
14. Always turn off the machine when leaving the work.
15. Apply eye drops after welding is over for the day, to relieve the strain on the eyes.
16. While welding, stand on dry footing and keep the body insulated from the
electrode and any bare parts of the electrode holder and the work.

30
4.19 Experiment Details

The TIG welding process parameters towards the development of welded joints are
fabricated developed and analysed for the weld quality parameters temperature
distribution, residual stresses and weld distortions.
The TIG welding machine specification machine used in this process is shown below in
table 4.

Table 4 Specification of machine

Parameter Specification

Supply Voltage 30-450Volts

Frequency 50

Phase 3Phase

Max Input Amps(Current) 40-80Amp

KVA 30

Range of hand amps(Current) 40-450Amps

Shielding Gases Argon

Tungsten Electrode 2% Thoriated tungsten

Polarity DC-DCEN

Work Piece 300x150x10mm

31
4.20 Experimental Results

The experimental work is carried out on the SS316 plates of 0.3x0.15x0.01m dimensions
by following the sequence of operations by varying the parameters as shown in the table
4.1

Table 4.1 Process parameters

PARAMETER UNIT LEVEL-1 LEVEL-2

S.NO

1 Welding AMP 70 80
Current
2 Welding VOLT 14 15
Voltage
3 Thickness of Meter 0.01 0.02
the Plate
4 Welding Speed mm/sec 1.5 2.5

Fig 4.8 Experiment Plates

32
4.21 Weld Experiment Data

Table 4.2 Experimental Data

S No Current Voltage Area Welding Heat Flux

(Amp) (Volt) (mm2 ) Speed (W/m2)
(mm/sec)
1 70 15 1350 1.5 0.46E6
2 80 15 1350 2.5 0.53E6

Table 4.3 Experimental results

Welding
Voltage Current
Area Speed Efficiency Distortion
(Volt) (Amp) 2
(mm ) (mm/sec) (%) (deg)
15 80 1350 2.5 0.6 1.3

15 70 1350 1.5 0.6 1

33
 Chapter 5
FINITE ELEMENT METHOD

The basic idea in the Finite Element Method is to find the solution of complicated
problems with relatively easy way. The Finite Element Method has been a powerful tool
for the numerical solution of a wide range of engineering problems. Applications range
from deformation and stress analysis of automotive, aircraft, building, defense, and
missile and bridge structures to the field of analysis of dynamics, stability, fracture
mechanics, heat flux, fluid flow, magnetic flux, seepage, and other flow problems. With
the advances in computer technology and CAD systems, complex problems can be
modeled with relative ease. Several alternate configurations can be tried out on a
computer before the first prototype is built. The basics in engineering field are must to
idealize the given structure for the required behaviour. In the Finite Element Method, the
solution region is considered as many small, interconnected sub regions called Finite
elements.

Most often it is not possible to ascertain the behaviour of complex continuous systems
without some form of approximations. For simple members like uniform beams, plates
etc., classical solutions can be sought by forming differential and/or integral equations
through structures like machine tool frames, pressure vessels, automobile bodies, ships,
aircraft structures, domes etc., need some approximate treatment to arrive at their
behaviour, be it static deformation, dynamic properties or heat conducting property.
Indeed these are continuous systems with their mass and elasticity being continuously
distributed. The classical differential equation solution approach leads to intractability.
To overcome this, engineers and mathematicians have from time to time proposed
complex structures, which are defined using a finite number of well-defined components.
Such systems are then regarded as discrete systems.

34
5.1 Historical Background
The Finite Element Method has been presented in 1956 by Turner, Clough, Martin and
Topp. The name Finite Element Method was first coined by R.W.Clough. Important early
contributions were those of J.H.Argyris and O.C.Zienckiwicz and Y.K.Cheung. Since the
early 1960’s, a large amount of research has been devoted to the technique, and a very
large number of publications on the Finite Element Method are now available. The Finite
Element Method was initially developed for structural mechanics but later on it was
applied to heat transfer, fracture mechanics, flow and coupled field problems.

5.2 Need For Finite Element Method

To predict the behaviour of structure the designer adopts three tools such as analytical,
experimental and numerical methods. The analytical method is used for the regular
sections of known geometric entities or primitives where the component geometry is
expressed mathematically. The solution obtained through analytical method is exact and
takes less time. This method cannot be used for irregular sections and the shapes that
require very complex mathematical equations. On the other hand the experimental
method is used for finding the unknown parameters of interest. But the experimentation
requires a testing equipment and a specimen for each behaviour of requirement. This in
turn, requires a high initial investment to procure the equipment and to prepare the
specimens. The solution obtained is exact by the time consumed to find the results and
during preparation of specimens also. There are many numerical schemes such as finite
difference methods Finite Element Method, boundary element and volume method, finite
strip and volume method and Boundary integral methods etc., are used to estimate the
approximate solutions of acceptably tolerance.

5.3 The Process of Finite Element Method

The Finite Element Method is used to solve physical problems in engineering

analysis and design. The physical problems typically involve an actual structure

35
component subjected to certain loads. The idealization of the physical problem to a
mathematical model requires certain assumptions that together lead to differential
equations governing the mathematical model. The Finite Element Analysis solves the
mathematical model, which describes the physical problem. The FEM (Finite Element
Method) is a numerical procedure; it is necessary to assess the solution accuracy. If the
accuracy criteria are not met, the numerical solution has to be repeated with refined
solution parameters until a sufficient accuracy is reached.
It is clear that the Finite Element solution will solve selected mathematical model
with all the assumptions, which reflects on the predicted response. The approximate
selection of mathematical model will influence the accuracy of the solution. The
mathematical model is solved and checked for the accuracy then refinement is made if
required. Depending upon the level of accuracy, the optimization of section or shape is
performed by linking the optimization techniques with Finite Element Method.

5.4 Field And Boundary Conditions

The field variables such a displacements, strains and stresses must satisfy the
governing conditions, which can be mathematically expressed in the form of differential
equations.
For structure mechanic problems the boundary conditions may be kinematic i.e.,
where the displacements (and slopes i.e., derivative of displacement) may be prescribed,
or static i.e., where forces (and moments) may be prescribed. Initial values may be given
in the problems where time is involved. The specified temperature or heat flow/heat flux
or convections may be specified in thermal analysis.

5.5 Steps Involved In Finite Element Modeling

The method is based on stiffness analysis. Stiffness is defined as the force required for
unit displacement and is the reciprocal of flexibility. In this method the structure is
assumed to be built up of numerous connected tiny elements. From this comes the name
“Finite Element Method”. Extremely complex structures also can be simulated by proper

36
arrangement of these elements. The most commonly used elements are beams, plates and
solid prismatic shapes etc. The points interconnecting the elements are called nodes. The
broad steps in the finite element method when it is applied to structural mechanics is as
follows:

1. Divide the continuum into a finite number of sub regions (or elements) of simple
geometry such as line segments, triangles, quadrilaterals. (Square and rectangular
elements are subsets of quadrilateral), tetrahedrons and hexahedrons (cubes) etc.

2. Select key points on the elements to serve as nodes where conditions of

equilibrium and compatibility are to be enforced.

3. Assume displacement functions within each element so that the displacements at

each generic point depend on the nodal values.

4. Satisfy strain-displacement and stress-strain relationships within a typical

element.

5. Determine stiffness and equivalent nodal loads for a typical element using work
or energy principles.

6. Develop equilibrium equations for the nodes of the discritized continuum in terms
of the element contributions.

7. Solve the equilibrium for the nodal displacements.

8. Calculate support reactions at restrained nodes if displaced.

9. Determine strains and stresses at selected points within the elements.

5.6 Applications Of Finite Element Method

Finite Element Method comes under this category of discretization methods.

R.W.Clough appears to be the first to use this term of finite element. Since early 1960’s
there has been much progress In the method. The method requires a large number of
computations requiring a fast computer. In fact digital computer advances have been
responsible for the expanding usage of the Finite Element Method. The Finite Element
Method was initially developed to solve structural problems. Its use, of late, has been

37
rapidly extended to various fields. The diversity of applications of the method can be
seen from the following Table 5.1, which still by no means can be claimed as complete
since fields of usage are being continuously diversified.

Table 5.1 Application Areas of Finite Element Method

S.No. Fields Typical Examples

1. Structural Mechanics
(Deflection & Stress
Analysis
of Structures)

A. Two
Dimensional In plane stresses, stretching of plates, gravity dams, Axi-
Analysis symmetric solid shells, rocket, motors, machine parts such
as shafts, beam bridges etc.
B. Three
Dimensional 3-D trusses, space frames such as cranes, thin walled
Analysis structure like machine tools, transmission towers, nuclear
towers, nuclear reactors, ship structures, radar domes,
building dams, shell roofs, arches, drilling platforms etc.

C. Bending of Floor slabs, thin walls of machine tool structure, ship

Plates decks, aircraft and spacecraft panels.
2. Soil and Rock Foundation layers, rock joints, pavements, stability of
Mechanics excavation such as river banks, embarkments, open pit
and underground mining problems etc.

3. Thermal analysis and Transient and steady state temperature distribution,

Fluid mechanics thermal strain and stresses in mechanical and civil
structures. Flow towards wells, seepage through

38
 foundations. Fluid flows in pipes, canals etc.

4. Hydro-elasticity Hydrodynamic, Hydrostatic and Air bearings. Reservoir-

dam interactions, sloshing of liquids in flexible containers
etc.
5. Dynamics Natural frequencies and mode shapes of structures.
Response to arbitrary dynamic loading such as wind
explosions, water waves, earthquakes etc.
6. Noise Problems Determination of acoustic pressure fields in ducts and
enclosed spaces. Structural acoustic interaction problems
etc.
7. Coupled Field and Structural and thermal coupling residual stresses, contact
Contact Problems stresses and gap condition, air gap insulation.

8. Composites Analysis of layered shell and solids, FRP, ceramic and

metal matrix composites, interlaminar and boundary
layered stresses.
9. Fracture Mechanics Strain energy release rates, stress, intensity factor, J-
integrals.

5.7 FEA SOFTWARE – ANSYS

5.7.1 Introduction

Dr. John Swanson founded ANSYS Inc. in 1970 with a vision to commercialize the
concept of computer-simulated engineering, establishing himself as one of the pioneers of
Finite Element Analysis (FEA). ANSYS Inc. supports the ongoing development of
innovative technology and delivers flexible, enterprise-wide engineering systems that
enable companies to solve the full range of analysis problem, maximizing their existing

39
investments in software and hardware. ANSYS Inc. continues its role as a technological
innovator. It also supports a process-centric approach to design and manufacturing,
allowing users to avoid expensive and time-consuming “build and break” cycles. ANSYS
analysis and simulation tools give customers ease-of-use, data compatibility, multi-
platform support, and coupled-field multi-physics capabilities.

5.7.2 Evolution of ANSYS

ANSYS has evolved into multipurpose design analysis software program, recognized
around the world for its many capabilities. Today the program is extremely powerful and
easy to use. Each release hosts new and enhanced capabilities that make the program
more flexible, more usable, and faster. In this way, ANSYS helps engineers meet the
pressures and demands of the modern product development environment.

5.7.3 Overview of the program

The ANSYS is a flexible, robust design analysis and optimization package. The
software operates on major computers and operating systems, from PC’s to workstations
to supercomputers. ANSYS features file computability throughout the family of products
and across all platforms. ANSYS design data access enables user to import computer-
aided design models into ANSYS, eliminating repeated work. This ensures enterprise-
wide, flexible engineering solution for all ANSYS users.

5.7.4 Reducing design and manufacturing costs with ANSYS FEA

The ANSYS program allows engineers to construct computer models or transfer
CAD models of structures, products, components, or systems; apply operating loads or
other design performance conditions; and study physical responses, such as stress levels,
temperature distributions, or the impact of electromagnetic fields.
In some environments, prototype testing is undesirable or impossible. ANSYS design
optimization enables the engineers to reduce the number of costly prototypes, rigidity and
flexibility to meet objectives, and find the proper balance in geometric modifications.

40
 Competitive companies look for ways to produce the highest quality product at the
lowest cost. ANSYS FEA can help significantly by reducing the design and
manufacturing costs, and by giving engineers added confidence in the products they
design. FEA is the most effective when used at the conceptual design stage. It is also
useful when used later in manufacturing process to verify the final design before
prototyping.

5.8 Procedure for ANSYS Analysis

A static analysis can be either linear or non-linear. In this work we have considered
non-linear transient analysis.
The procedure for ANSYS analysis consists of three main steps:
1. Build the model.
2. Obtain the solution.
3. Review the results.

5.8.1 Build the Model

In this step, we specify job name and analysis title and then define the element types,
element real constants, material properties and the model geometry element types- both
linear and non-linear structural elements are allowed. The ANSYS element library
contains over 80 different element types. A unique number and prefix identify each
element type.
E.g.: PLANE-71, SOLID-96, BEAM-94 and PIPE-16.
5.8.2 Material Properties
Young’s modulus [Ex] must be defined for static analysis. If we have to apply inertia
loads [such as gravity], we define mass properties such as density [DENS]. Similarly if
we apply thermal loads [temperatures], we define coefficients of thermal expansion
[ALPX].

41
5.8.3 Obtain the Solution
In this step we define the analysis type and options, apply loads and initiate the finite
element solution. This involves three phases:
a. Pre-Processor phase
b. Solution phase
c. Post-Processor phase
The following Table 5.2 shows the brief description of the steps followed in each phase.
Table 5.2 Steps Description
Pre-Processing phase Solution phase Post-Processing phase
1. Geometry definitions 1. Element matrix formation 1. Post solution operation
2. Mesh generation 2.Overall matrix 2. Post data printout (for
triangularization reports)
3.Constraint and load 3.Calculation of 3. Post data scanning
definitions displacement, stress, etc.
4. Model displays 4. Post data display
5. Material definitions

5.8.4 Pre-Processor
Pre-Processor has been developed so that the same program is available on micro, mini,
super-mini and mainframe computer system. This allows easy transfer of models from
one system to the other.
Pre-Processor is an interactive model builder to prepare the finite element model and
input data. The solution phase utilizes the input data developed by the pre-processor, and
does the solution according to the problem definition. It creates input files to the
visualization of results on the graphics screen. It displays the displacements, stresses,
temperatures, etc. on the screen in the form of contours.

42
5.8.5 Model Generation (Solid Modeling)
It is generally more appropriate for large or complex models, especially 3-D models
over solid volumes.
• Allows us to work with relatively small number of data items.
• Supports the use of ‘primitives of areas and volumes’ (such as polygonal and
cylindrical volumes) and Boolean operations (integration, subtractions, etc.) for
the ‘top down’ construction of the model.
• Facilitates the use of ANSYS program’s design optimization features.
• It is required for adaptive meshing.
• Readily allows modifications to geometry.
• Facilitates changes to be made to the element distribution and it is not bound to
one analysis model.
• Requires large amount of CPU sometimes.
• For small and simple models, it is sometimes cumbersome requiring more data
entries than direct generation.
• Can ‘fail’ (the program will not be able to generate the finite element mesh) under
certain circumstances.
5.8.6 Geometric Definitions
There are four different geometric entities in pre-processor namely key points, lines,
areas and volumes. These entities can be used to obtain the geometric representation of
the structure. All the entities are independent of each other and have unique identification
labels.
• Key points: Key points are points in 3-D space. Key point is a basic entity and
usually the first entity to create. The key points can be generated by various ways;
by individual definition, by transferring existing key points and from the other
entities; e.g. intersection of two lines, key point at the corners etc.

• Lines: A line is generally a 3-D curve defined by using a parametric cubic

equation. Lines can be generated from a number of grids. Sweeping a specified

43
 grid about a given axis through a desired included angle can generate a circular
arc.

• Area: An area is a 3-D surface defined using a parametric cubic equation. Areas
can be generated using four key points or four-line method, depending on the
geometry. Some inbuilt areas like circle, rectangle, and polygon can be generated
directly to the required size.

• Volumes: Volume, in general, is a 3-D solid region defined by using a parametric

cubic equation. Similar to areas, volumes also have parametric directions. Using
two or four areas, they can be generated. Spinning an area about an axis with
another area can also generate volumes. Volumes of cylinder, prism and sphere
can be directly created to required sizes.

5.8.7 Mesh Generation

In Finite element analysis, the basic concept is to analyze the structure, which is an
assemblage of discrete pieces called elements that are connected together at a finite
number of points called nodes. Loading boundary conditions are then applied to these
elements and nodes. The network of elements is called mesh.

5.8.8 Finite Element Generation

The maximum amount of time, in finite element analysis, is spent on generating elements
and nodal data. Pre-processor allows the user to generate nodes and elements
automatically at the same time allowing control over size and number of elements. There
are various types of elements that can be mapped or generated on various geometric
entities.
Elements
The elements developed by various automatic element generation capabilities of pre-
processor can be checked by element characteristics that may need to be verified before
finite element analysis are connectivity, distortion index etc.
Nodes

44
 Generally user would not be defining nodes individually but rather use automatic
mesh generating capabilities of pre-processor. User can plot, erase, delete and search
nodes. Nodes can be defined easily by defining locations or by translating existing nodes.
Node Merging
Pre-processor automatically generates nodes on each meshed geometric entity. This
leads to coincident nodes (i.e. two or more nodes at within the certain tolerance) at the
common edge or faces of geometric entities. Node merge option will keep anyone of the
coincident nodes and delete all other coincident nodes.

Node Manipulation
In pre-processor node numbers can be re-sequenced with user defined starting
number. User can also delete unreferenced nodes (nodes not attached to any element) by
issuing only one command.

5.8.9 Boundary Conditions and Loading

After completion of finite elements model it has to be constrained and load has to be
applied to the model. User can define constraints and load in various ways. All
constraints and loads are assigned set 1-D, this helps the user to keep track of load cases.
Model Display: During the construction and verification stages of the model, it may be
necessary to view it from different angles. It is useful to rotate the model with respect to
the global system and view it from different angles. Pre-processor offers this capability.
By windowing feature, pre-processor also allows the user to enlarge a specific area of the
model for clarity and details. The hidden line removal, shrink option and boundary line
plotting feature enhances visualization of geometry and checking the continuity of the
model. Pre-processor also provides features like smoothness, scaling, regions, regions,
active set etc, for efficient model viewing and editing.

Setting Parameters: There are several parameters that the user can change during any
stage of modeling. The parameters include colors, labeling of various entities, radius of
key points, nodes, number of segments used to represent lines, and so on, During the

45
construction of complex models, it is more convenient to input certain part of model in a
coordinate system other than the global coordinate system.

5.8.10 Material Definitions

All elements are defined by nodes, which have only their location defined. In the case of
plate and shell elements there is no indication of thickness. The thickness can be given as
an element property. Property tables for a particular set –ID have to be input. Different
types of elements have different properties, for e.g.
Beams : Cross sectional area, moment of inertia, etc.
Springs : Stiffness
Shells : Thickness
The user also needs to define material properties of the elements. For linear static
analysis, modulus of elasticity and Poisson’s ratio need to be provided. For heat transfer,
coefficient of thermal expansion, densities etc. are required. They can be given to the
elements by the material property set ID.

5.9 Solution
The solution phase deals with the solution of the problem according to the problem
definitions. All the tedious work of formulating and assembling of matrices are done by
the computer and finally displacements and stresses are given as output.
Some of the capabilities of ANSYS are given below.
1. Structural static analysis.
2. Structural dynamic analysis.
3. Structural buckling analysis.
i. Linear buckling.
ii. Non-linear buckling.
4. Structural non-linear ties.
5. Static and dynamic kinematics analysis.
6. Thermal analysis.
7. Electromagnetic field analysis.

46
 8. Electric field analysis.
9. Fluid flow analysis.
i. Computational fluid dynamics.
ii. Pipe flow.
10. Coupled-field analysis.
11. Piezoelectric analysis.

5.10 Structural Static Analysis

The structural static analysis capabilities in the ANSYS program are used to determine
the displacements, stresses, strains and forces that occur in a structure or component as a
result of applied loads. Static analysis is appropriate for solving problems in which the
time-dependent effects of inertia and damping do not significantly affect the structures
response. This analysis type can be used for many applications, such as determining the
stress intensities in fillets of mechanical components or predicting the stress in a structure
resulting from a temperature distribution.

Most mechanical and structural engineers are familiar with this type of analysis and
have probably solved numerous static problems using classical analysis methods or
equations from engineering handbooks. The governing equations for static analysis in the
ANSYS program is:
[K] {u} = {F}
where [K] is the structural stiffness matrix and {u} is the displacement vector and {F}
is the force vector.
The force vector, {F}, can include concentrated forces, thermal loads, pressures and
inertia loads.
Static analysis in the ANSYS program can also include non-linearity such as
plasticity, creep, large deflection, large strain and contact surfaces. Applying the load
gradually so that an accurate solution can be obtained usually performs a non-linear static
analysis.

47
5.11 Post Processor

The post-processing phase of the ANSYS program follows the preprocessing and
solution phases. With this portion of the program, the user may easily obtain and operate
on the results calculated in the solution phase through a very complete set of user-friendly
post-processing features. These results may include displacements, temperatures, strains
and stresses, velocities and heat flows. The output from the post-processing phase of the
program is in display and/or tabular report form. Because the post-processing phase is
fully integrated with the ANSYS preprocessing and solution phases, the user can examine
results immediately.
It is a powerful user-friendly post-processing program. Using interactive color
graphics, it has extensive plotting features for displaying results obtained from FEM. One
picture of analysis results can often reveal in seconds what would take engineer hours to
assess from numerical printout. The engineer may also see important aspect of the results
that could be easily missed in stock of printout.
Employing state of the art image enhancement techniques, it facilities viewing of
contours of stresses, displacements, temperatures etc.

5.12 Residual Stresses

Residual stresses are the stresses that are inside or locked into a component or assembly
of parts. The internal state of stress is caused by mechanical or thermal processing of the
parts or both. Common examples of these are bending, rolling or forging a part. Also the
thermal stresses are induced during Welding.
These residual stresses can be sufficient to cause a metal part to suddenly split into
two or more pieces after it has been resting on a floor or table without any external load
being applied. This is not a common occurrence but experienced people in the metal
working industry have witnessed this phenomenon.
Residual stresses can play a significant role in explaining or preventing failure of a
component at times.

48
Thermal residual stresses are primarily due to differential expansion when a metal is
heated or cooled. The two factors that control this are Thermal treatment (heating or
cooling) and Thermal restraint. Both the thermal treatment and restraint of the component
must be present to generate residual stresses.

5.13 Sources of Residual Stresses

Due to the non-uniform temperature distribution during the thermal cycle, incompatible
strains lead to thermal stresses. These incompatible strains due to dimensional changes
associated with solidification of the weld metal, metallurgical transformations and plastic
deformation are the sources of residual stresses and distortion.
Welding induced residual stresses and distortion can play a very important role in the
reliable design of welded joints and welded structures.

5.14 Effects of Various Factors on Residual Stresses

Residual stresses mainly depend on the following factors:

Effect of heat input value.

Effect of temperature dependency on material properties.

Effect of radiation and phase changes.

5.15 Development of Welding Residual Stresses

Residual stresses are formed by the plastic deformations during the thermal cycle of
welding. During welding, the high temperature at the weld region causes compressive
stress due to thermal expansion. This compressive stress exceeds the yield stress at the
corresponding temperature. Away from the weld, the stress is tensile equilibrating the
compressive stress over the analysis plane.
The stress reverses sign from compressive to tensile at locations that have
plastified during welding, and a band of residual stresses at the material yield level (at
room temperature) is developed at the weld region. Away from the weld the residual
stress is compressive.

49
 Chapter 6
MODELING OF TIG WELDING USING FEA

6.1 Modeling
The process of forming butt welds that joins two steel plates was simulated.
The overall dimensions adopted are 0.3 x 0.15 x 0.01 meters. The welding procedure is
modeled as a single pass in this analysis. The weldment was assumed to be symmetric so
that only one half of the model was analyzed. No penetration and overfill of the
weldment were considered.
The FE analysis was carried out in two steps. A non-linear transient thermal analysis
was conducted first to obtain the global temperature history generated during the welding
process. A stress analysis was then developed with the temperatures obtained from the
thermal analysis used as loading to the stress model. The general purpose FE package
ANSYS was used for both thermal and stress analysis performed sequentially. The mesh
used in the stress analysis was identical to that in the thermal analysis.

Fig 6.1 Symmetric model showing the areas

50
Fig 6.2 2D Mesh model of the weld plate.

Fig 6.3 3D Mesh model of the weld plate

51
6.2 Problem Definition
A Finite Element (FE) simulation of the welding process yielding the welding-induced
residual stresses in a butt-welded plate is presented. In fusion welding, a weldment is
locally heated by the welding heat source. Due to the non-uniform temperature
distribution during the thermal cycle, incompatible strains lead to thermal stresses. These
incompatible strains due to dimensional changes associated with solidification of the
weld metal (WM), metallurgical transformations, and plastic deformation, are the sources
of residual stresses and distortion. Welding-induced residual stresses and distortion can
play a very important role in the reliable design of welded joints and welded structures.
Here, a finite element simulation of the welding process yielding the temperature
distribution, welding-induced residual stresses and the distortion in a butt-welded plate
are presented.

Fig 6.4 Schematic diagram of welding test plate

6.3 Material Used

SS316 material is used. Grade 316 is the standard molybdenum-bearing grade, second in
importance to 304 amongst the austenitic stainless steels. The molybdenum gives 316
better overall corrosion resistant properties than Grade 304, particularly higher resistance
to pitting and crevice corrosion in chloride environments. It has excellent forming and
welding characteristics. It is readily brake or roll formed into a variety of parts for
applications in the industrial, architectural, and transportation fields. Grade 316 also has

52
outstanding welding characteristics. Post-weld annealing is not required when welding
thin sections

Grade 316L, the low carbon version of 316 and is immune from sensitisation (grain
boundary carbide precipitation). Thus it is extensively used in heavy gauge welded
components (over about 6mm). Grade 316H, with its higher carbon content has
application at elevated temperatures, as does stabilised grade 316Ti.

The austenitic structure also gives these grades excellent toughness, even down to
cryogenic temperatures.

Excellent weldability by all standard fusion methods, both with and without filler metals.
AS 1554.6 pre-qualifies welding of 316 with Grade 316 and 316L with Grade 316L rods
or electrodes (or their high silicon equivalents). Heavy welded sections in Grade 316
require post-weld annealing for maximum corrosion resistance. This is not required for
316L. Grade 316Ti may also be used as an alternative to 316 for heavy section welding.

6.4 Material Properties

Several different material have been used in structures where welding is involved, with
low carbon steel being the most common. The weldment material properties employed in
this work were of SS316.

Temperature dependent material properties were needed in the analyses. The modulus of
elasticity is a measure of the stiffness of a material. A higher modulus material is more
likely to resist distortion. The amount of expansion or contraction of a metal will undergo
during a heating or a cooling cycle depends on the coefficient of thermal expansion.
Thermal conductivity gives a measure of the ease of heat flow through a material.

The selected material properties are Young’s Modulus, Poisson’s ratio, thermal
conductivity, specific heat, thermal expansion coefficient and density.

The melting point temperature of SS316 is 1450o C.

53
Young’s Modulus=193Gpa

Poisson’s ratio=0.27

The table 6.1 below gives the temperature dependent material properties of SS316.

Table 6.1 Temperature- dependent material properties

.
T (K) E (GPa) Density α 0 (10-6/0C) K (W/m 0K) C (KJ/Kg 0K)
300 194.18 8000 15.156 13.40 468.0
400 188.49 8000 16.05 15.20 504.0
500 182.02 8000 16.933 16.75 527.0
600 174.29 8000 17.511 18.30 550.0
700 166.17 8000 17.946 19.80 563.0
800 157.96 8000 18.297 21.30 576.0
900 148.63 8000 18.592 22.75 589.0
1000 136.50 8000 18.847 24.20 602.0

6.5 Element Description

PLANE 55
PLANE55 can be used as a plane element or as an axisymmetric ring element with a 2-D
thermal conduction capability. The element has four nodes with a single degree of
freedom, temperature, at each node.
The element is applicable to a 2-D, steady state or transient thermal analysis. If the model
containing the temperature element is also to be analyzed structurally, the element should
be replaced by an equivalent structural element (such as PLANE42).

54
 Fig 6.5 Plane 55 Geometry

PLANE55 Input Data

The geometry, node locations, and the coordinate system for this element are shown in
Figure 6.5 "PLANE55 Geometry". The element is defined by four nodes and the
orthotropic material properties. Heat generation rates may be input as element body loads
at the nodes. . If the node I heat generation rate HG(I) is input, and all others are
unspecified, they default to HG(I). With this option the velocities VX and VY must be
input as real constants (in the element coordinate system). Also, temperatures should be
specified along the entire inlet boundary to assure a stable solution. With mass transport,
you should use specific heat (C) and density (DENS) material properties instead of
enthalpy (ENTH).

PLANE55 Input Summary

Nodes: I, J, K, L
Degrees of Freedom: TEMP
Material Properties: KXX, KYY, DENS, C
Surface Loads: Convection or Heat Flux and Radiation

55
PLANE55 Output Data

The solution output associated with the element is in two forms:

• Nodal temperatures included in the overall nodal solution

• Additional element output.

For an axisymmetric analysis the face area and the heat flow rate are on a full 360° basis.
Convection heat flux is positive out of the element; applied heat flux is positive into the
element. The element output directions are parallel to the element coordinate system. A
general description of solution output is given in Solution Output and of post processing
data in Triangle, Prism and Tetrahedral Elements.

PLANE55 Assumptions and Restrictions

• The element must not have a negative or a zero area.

• The element must lie in an X-Y plane as shown in Figure: "PLANE55 Geometry"
and the Y-axis must be the axis of symmetry for axisymmetric analyses. An
axisymmetric structure should be modeled in the +X quadrants.
• A triangular element may be formed by defining duplicate K and L node numbers
as described in Triangle, Prism and Tetrahedral Elements.
• The specific heat and enthalpy are evaluated at each integration point to allow for
abrupt changes (such as melting) within a coarse grid of elements.
• If the thermal element is to be replaced by a PLANE42 structural element with
surface stresses requested, the thermal element should be oriented with face IJ or
face KL as a free surface. A free surface of the element (that is, not adjacent to
another element and not subjected to a boundary constraint) is assumed to be
adiabatic.
• Thermal transients having a fine integration time step and a severe thermal
gradient at the surface will also require a fine mesh at the surface.
• If KEYOPT (8) > 0, unsymmetric matrices are produced.

56
SOLID 70

SOLID70 has a 3-D thermal conduction capability. The element has eight nodes with a
single degree of freedom, temperature, at each node. The element is applicable to a 3-D,
steady-state or transient thermal analysis. The element also can compensate for mass
transport heat flow from a constant velocity field. If the model containing the conducting
solid element is also to be analyzed structurally, the element should be replaced by an
equivalent structural element (such as SOLID45).

Fig 6.6 SOLID70 geometry

The geometry, node locations, and the coordinate system for this element are shown in
Figure "SOLID70 Geometry". The element is defined by eight nodes and the orthotropic
material properties. A prism-shaped element, a tetrahedral-shaped element, and a
pyramid-shaped element may also be formed as shown in Figure "SOLID70 Geometry".
Orthotropic material directions correspond to the element coordinate directions.

57
Element loads are described in Node and Element Loads. Convection or heat flux (but
not both) and radiation may be input as surface loads at the element faces as shown by
the circled numbers on Figure "SOLID70 Geometry".

Degrees of Freedom: TEMP

Material Properties: KXX, KYY, KZZ, DENS, C

SOLID70 Output Data

The solution output associated with the element is in two forms:

• Nodal temperatures included in the overall nodal solution

• Additional element output.

Convection heat flux is positive out of the element; applied heat flux is positive into the
element.

SOLID70 Assumptions and Restrictions

• The element must not have a zero volume. This occurs most frequently when the
element is not numbered properly.
• Elements may be numbered either as shown in Figure "SOLID70 Geometry" or
may have the planes IJKL and MNOP interchanged.
• A prism or tetrahedron shaped element may be formed by defining duplicate node
numbers as described in Triangle, Prism and Tetrahedral Elements.
• The specific heat and enthalpy are evaluated at each integration point to allow for
abrupt changes (such as for melting) within a coarse grid.
• If the thermal element is to be replaced by a SOLID45 structural element with
surface stresses requested, the thermal element should be oriented such that face
I-J-N-M and/or face K-L-P-O is a free surface.
• A free surface of the element (that is, not adjacent to another element and not
subjected to a boundary constraint) is assumed to be adiabatic.

58
 • Thermal transients having a fine integration time step and a severe thermal
gradient at the surface will also require a fine mesh at the surface.
• If KEYOPT(8) > 0, unsymmetric matrices are produced

6.6 Thermal loading

The input value i.e. the thermal loading during thermal analysis is given according to the
graph shown in the figure below.

Fig 6.7 Thermal loading function

Time is plotted on the X-axis and the heat flux is plotted in the Y-axis. The graph begins
from 0 seconds and is considered up to 1100 seconds. Ramp input is given for the first 10
seconds. Step input is given up to 100 seconds. Ramp input is again given up to 1100
seconds. This is because the value of heat input first increases gradually, when welding is
started, until it reaches a certain value. It then remains stable for a very less amount of
time and then the heat decreases gradually till the temperature of the plate reaches the
value of room temperature.
The amount of heat input was found as the product of arc efficiency, voltage, and
current, which were taken equal to 0.7, 15 V and 80 A, respectively in this analysis.

59
The maximum value of heat flux calculated is 0.62x106 W/m2 .
In the thermal analysis, the heat input was in three load steps corresponding to t1- t3
as shown in the figure. The nodal temperature solutions obtained from the thermal
analysis were read as loading into the stress analysis. In order to capture used, the greater
the computational time and the larger the store space required. The residual stresses
induced due to the heating and cooling cycle, the temperature history had to be read at a
sufficiently large number of time points. However, the greater the number of thermal
solution steps.

6.7 Boundary Conditions

6.7.1 For thermal analysis

In a symmetrical model, convection is given on the areas as shown in figure.
The area of one plate, which is in contact with the other plate in a butt joint, is assumed to
be insulated i.e., the heat flow across this area is zero.
The insulation is applied by selecting the corresponding nodes.
The value of the convective film coefficient is 20 W/m2ºC
The room temperature of 40 oC was given to the remaining areas of the plate.

Fig 6.8 Thermal boundary conditions applied to the plate

60
6.7.2 For static analysis:

After switching from thermal analysis to static analysis, the boundary conditions assumed
should be applied. In this model it is assumed that the area, as shown in figure, is
constrained in all directions. That is, all degree of freedom is zero.

Fig 6.9 Boundary conditions applied to the plate in static analysis

6.8 Heat Transfer Analysis

The first part of the finite element simulation of TIG welding is heat transfer analysis. In
the finite element formulation, this equation can be written for each element as follows

[C (T)] {Ť}+ [K (T)]{T} = {Q (T)} (1)

This analysis requires an integration of the heat conduction equation with respect to time.
The Crank – Nicholson/Euler theta integration method is applied to solve these system
equations. This element type has a three-dimensional thermal conduction capability. The
heat input from the welding electrode was modeled by using heat flux as the input for the

61
heat transfer from the rod to the work piece. This heat flux is based on the welder setting
and the efficiency of the arc.
Q = η VI

6.9 Mechanical Analysis

To evaluate the distortion and residual stress distribution the heat transfer analysis was
performed first in order to find nodal temperatures as a function of time. Then in the
second part of the analyses, a non-linear structural analysis was carried using the
temperature distributions, which were obtained from the heat transfer analysis.

Table 6.2 Values used in simulation

S.No. Voltage, V Current, I Area, A Efficiency, Heat, Heat flux,
(volts) (amperes) (m²) x10-6 η Q=VIη q=Q/A
(Watts) (W/m²)
x10+6

1. 15 80 4.5x300 0.6 720 0.53

2. 15 70 4.5x300 0.7 735 0.54
3. 15 80 4.5x300 0.8 960 0.71
4. 15 70 4.5x300 0.9 945 0.7
5. 15 80 4.5x300 0.75 900 0.66
6. 15 70 4.5x300 0.65 682.5 0.50

6.10 Input Calculations

The value of current supplied in this experiment is 80 Amperes and the value of voltage
supplied is 15 Volts.

62
6.11 Calculation of Heat Flux (q)
q = Q/A
where Q = V * I * η
= 15 x 80 x 0.7
= 840 W
-6
A = 4.5 x 300 x 10 m²
Therefore, q = (840)/(4.5 x 300 x 10-6)
= 0.62 x 10+6 W/m²
= 0.62E6W/m2

6.12 Thermal and Structural analysis of TIG welded workpiece using

FEA
1) Thermal Analysis Governing Equations

K (δ²T/ δx² + δ²T/ δy²+ δ²T/ δz²)- q+ h(T-T ὰ)=0

k= Thermal conductivity
T= Temperature (initial)
X= width of plate
Y= length of plate
Z= Thickness of plate
q = displacement function
h = Heat transfer co-efficient
Tὰ= exposed temperature

[C]{T}= {f}
[C]= Shape matrix
{ f }= force function

63
[K*] { q }= {F}
[K*]= stiffness matrix
[K*]= AE/L 1 -1
-1 1
A=Area
E= Young’s modulus
{F}= force function
L= Length of a material

[B]= Strain displacement matrix

[D]= Elasticity matrix

64
 Chapter 7
RESULTS AND DISCUSSIONS

Based on the results from the simulation and analysis , the simplified modeling process
for simulating welding-induced residual stresses and distortion using a general-purpose
FE package described here is reliable and instructive.

The main features of the simulation are:

1. A 2-D plain strain model

2. Use symmetrical feature of the model to reduce the program running time and space
required

3. Simulating the 3-D effect of the arc traveling by applying a ramped heat input
function. Adopting uncoupled thermal and stress analyses, the temperature history results
are read from the thermal analysis as loading to the stress analysis. The thermal analysis
should be transient to trace the rapid change of temperature with time while a static
analysis can be adopted for the stress analysis. However, a significant number of time
points, at which the temperature results are to be read into the stress analysis, should be
defined to capture the temperature gradient and give accurate residual stress results using
the load steps option.

4. Radiation and latent heat from phase transformation can be ignored to simplify the
modeling procedure.

65
7.1 Thermal Results

A maximum temperature of 505.187 o C is found at the weld joint.

Fig 7.1 Temperature distribution at the weld zone

This fig 7.1 shows the temperature distribution at the weldzone after applying
thermal boundary conditions. The above figure shows that the maximum
temperature is observed at the weld zone region where the heatflux is applied.
Here heat flux is applied where the electrode initially comes in contact with the metal
plate. Hence maximum temperature 505 ºC is obtained at that contact.

66
Variation of colors represents the variation of temperature along the plate. The different
values of the temperature (in centigrade) are shown in the above figure.

Fig 7.2 Temperature distribution away from the weld zone

The fig 7.2 shows the temperature distribution which is decreasing away from the weld
zone.
The above figure shows the temperature distribution which is the cooling step which
indicates the slow decrease in temperature after heating step and again it slowly reaches
the room temperature as shown in fig 7.3.

67
 Fig 7.3 Temperature distribution at the cooling step

Fig 7.4 Variation of temperature with time at weld zone

The fig 7.4 shows the welding curve which indicates the heating and cooling step.

68
 Fig 7.5 Variation of temperature with time away from weld zone

Fig 7.6 Variation of temperature along the distance away from weld zone

The above graphs are obtained by picking a node near the weld region. It shows the
temperature distribution over a period of time and distance. The temperature distribution
obtained gradually increases to a max temperature of 504 oC during the heating step and
decreases to room temperature during the cooling step at a constant rate.
The fig7.6 shows the decrease in temperature as it moves away from the weld zone.

69
7.2 Temperature variation by varying weld parameters
1) Voltage variation
2) Efficiency
3) Thickness of the plate
7.2.1 Voltage variation

Fig 7.7 Variation of temperature with time at the weld zone for 12V

Fig 7.8 Variation of temperature with time at the weld zone for 13V

70
Fig 7.9 Variation of temperature with time at the weld zone for 14V

Fig 7.10 Variation of temperature with time at the weld zone for 15V

71
 Table 7.1 Voltage variation
Welding Welding
Voltage Efficiency Area Heatflux Temperature
Current
Distribution
(Volt) (%) (mm2) (W/m2)
(Amp) (o C)

80 12 0.7 1350 0.49E6 294.5

80 13 0.7 1350 0.53E6 320.462

80 14 0.7 1350 0.58E6 350.197

80 15 0.7 1350 0.62E6 372.186

The temperature is gradually increasing as in table 7.1 as the voltage is varied in an

increasing order .

72
7.2.2 Efficiency Variation
The efficiency is varied from 0.6 to 0.9 and the temperature distributions are shown
below

Fig 7.11 Variation of temperature with time at the weld zone for 0.6 efficiency

Fig 7.12 Variation of temperature with time at the weld zone for 0.65 efficiency

73
Fig 7.13 Variation of temperature with time at the weld zone for 0.7 efficiency

Fig 7.14 Variation of temperature with time at the weld zone for 0.8 efficiency

74
Fig 7.15 Variation of temperature with time at the weld zone for 0.85 efficiency

Fig 7.16 Variation of temperature with time at the weld zone for 0.95 efficiency

75
 Table 7.2 Efficiency variation
Welding Welding Efficiency Area Heatflux Temperature Distribution
Voltage 2 (o C)
Current (%) (mm ) (W/m2)
(Volt)
(Amp)

80 15 0.6 1350 0.53E6 320.462

80 15 0.65 1350 0.57E6 350.197

80 15 0.7 1350 0.62E6 372.186

80 15 0.75 1350 0.66E6 379.16

80 15 0.8 1350 0.71E6 405.16

The temperature is gradually increasing as in table 7.2 as the efficiency is varied in an

increasing order.

76
7.2.3 Thickness Variation

Fig 7.17 Variation of temperature with time at the weld zone for 10mm thick plate

Fig 7.18 Variation of temperature with time at the weld zone for 15mm thick plate

77
Fig 7.19 Variation of temperature with time at the weld zone for 20mm thick plate

Fig 7.20 Variation of temperature with time at the weld zone for 25mm thick plate

78
 Table 7.3 Thickness variation

Welding Welding Efficiency Area Heatflux Thickness Temperature

Voltage Distribution
Current (%) (mm2) (W/m2) (mm)
(o C)
(Volt)
(Amp)

80 15 0.7 1350 0.62E6 10 372.186

80 15 0.7 1350 0.62E6 15 301.753

80 15 0.7 1350 0.62E6 20 283.986

80 15 0.7 1350 0.62E6 25 271.186

The temperature is gradually decreasing as in table 7.3 as the thickness of the plate is
varied. As the thickness of the plate is increased from 10mm to 25mm the temperature is
decreasing to a lower value.

79
7.3 Structural Results

Fig 7.21 Von Misses Stresses

This Fig 7.21 shows the thermal stresses in the plate. For finding the thermal stress,
temperature distribution from the thermal analysis is coupled to the structural analysis
.The difference in the temperature obtained in thermal analysis causes the thermal
stresses to occur and the thermal stresses are maximum at the weld portion. The
maximum stress of 136 MPa is obtained in this process.

80
 Fig 7.22 X- Direction Displacement
The figure indicates the displacement in X direction which is caused as a a result of
thermal stresses in the plate. The deformation is the result of thermal stresses or the
residual stresses in the plate. The displacement along the X-Direction is 0.0253mm as
shown in Fig 7.22.

Fig 7.23 Y-Direction Displacement

The displacement along the Y-Direction is 0.0474mm as shown in Fig 7.23

81
 Fig 7.24 Resultant Displacement

The resultant displacement obtained in the weld plate is 0.043mm as shown in Fig7.24.
The main cause for the deformation in the plate are the thermal stresses in the plate
which are produced because of the temperature difference in thermal analysis.

82
 Chapter 8
CONCLUSIONS AND FUTURE SCOPE OF WORK

The following conclusions are drawn from the present work

8.1 Conclusions

Development of a 3-dimensional coupled thermo-mechanical finite element model of a

TIG welding process was described in this work.

1. By conducting experiments with weld parameters the heat flux is calculated and is
used as input for the finite element analysis in butt-welding of plates.

2. Analysis of this weld joint gives useful information for the modeling of the process
under different process conditions without carrying out real experiments on the machine,
this saves money, time and resources.

3. The results obtained from the welding process simulation explain about the
temperature and stress distributions from the weld region to the other regions.

4. Maximum temperature of 503°C was observed by applying the heat flux value of
0.84x106 W/m2

5. Variation of temperature by varying welding voltage, joint efficiency and thickness of

the weld plate is observed.

6. The temperature is gradually increasing from 294 to 370 o C as the voltage is varied
from 12 to 15V

83
7. The temperature is gradually increasing from 320 to 501 o C as the joint efficiency is
varied from 0.6 to 0.9

8. The temperature is gradually decreasing from 372 to 271 o C as the thickness of the
plate is varied from 10 to 25mm

9. Coupled field analysis is carried out to estimate the residual stresses. The maximum
induced stress observed due to the temperature distribution of 503 o C is 136 MPa.

10. The resultant distortion observed in the weld plate is 0.043mm

8.2 Future Scope

1. Due to very short duration of weld time, heat losses are not considered. For accurate
modeling heat transfer and dissipation can be considered.

2. Multipass welding simulation can be done for more accurate results for any geometry.

84
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