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Acta Metall Sin  2017, Vol. 53 Issue (11): 1532-1540    DOI: 10.11900/0412.1961.2017.00007
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Influence of Multi-Thermal Cycle and Constraint Condition on Residual Stress in P92 Steel Weldment
Dean DENG1,2(), Sendong REN1, Suo LI1, Yanbin ZHANG1
1 College of Materials Science and Engineering, Chongqing University, Chongqing 400045, China
2 State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China
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Abstract  

P92 steel is a typical 9%~12%Cr ferrite heat-resistant steel with good high temperature creep resistance, relatively low linear expansion coefficient and excellent corrosion resistance, so it is one of important structural materials used in supercritical thermal power plants. Fusion welding technology has been widely used to assemble the parts in thermal power plant. When the supercritical unit is in service, its parts are constantly subjected to combination of tensile, bending, twisting and impact loads under high temperature and high pressure, and many problems such as creep, fatigue and brittle fracture often occur. It has been recognized that welding residual stress has a significant impact on creep, fatigue and brittle fracture, so it is necessary to study the residual stress of P92 steel welded joints. The evolution and formation mechanism of welding residual stress in P92 steel joints under multiple thermal cycles were investigated in this work. Based on SYSWELD software, a computational approach considering the couplings among thermal, microstructure and mechanics was developed to simulate welding residual stress in P92 steel joints. Using the developed computational tool, the evolution of residual stress in Satoh test specimens was studied, and welding residual stress distribution in double-pass welded joints was calculated. In the numerical models, the influences of volume change, yield strength variation and plasticity induced by phase transformation on welding residual stress were taken into account in details. Meanwhile, the hole-drilling method and XRD method were employed to measure the residual stress distribution in the double-pass welded joints. The simulated results match the experimental measurements well, and the comparison between measurements and predictions suggests that the computational approach developed by the current study can more accurately predict welding residual stress in multi-pass P92 steel joints. The simulated results show that the longitudinal residual stress distribution around the fusion zone has a clear tension-compression pattern. Compressive longitudinal residual stresses generated in the fusion zone and heat affected-zone (HAZ) in each pass, while tensile stresses produced near the HAZs. In addition, the numerical simulation also suggests that the transverse constraint has a large influence on the transverse residual stress, while it has an insignificant effect on the longitudinal residual stress.

Key words:  solid-state phase transformation      residual stress      numerical simulation      multi-thermal cycle      Satoh test     
Received:  06 January 2017     
ZTFLH:  TG404  
Fund: Supported by National Natural Science Foundation of China (No.51275544) and Graduate Scientific Research and Innovation Foundation of Chongqing (No.CYB16017)

Cite this article: 

Dean DENG, Sendong REN, Suo LI, Yanbin ZHANG. Influence of Multi-Thermal Cycle and Constraint Condition on Residual Stress in P92 Steel Weldment. Acta Metall Sin, 2017, 53(11): 1532-1540.

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https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00007     OR     https://www.ams.org.cn/EN/Y2017/V53/I11/1532

Fig.1  Schematics of dimensions of welded joint, beads distribution, and the locations of XRD and hole-drilling (HD) measurements (unit: mm)
Fig.2  Schematic of couplings among thermal, metallurgical and mechanical analysis
Fig.3  Flowchart of finite element method (FEM) simulation
Fig.4  Schematic of the model of constrained heating-cooling test (Satoh test)
Case PT-1 PT-2
A 1400 600
B 1400 1400
C 600 1400
Table 1  Simulation cases of Satoh test (℃)
Fig.5  3D finite element model
Fig.6  Schematics of model in free condition (a) and constraint condition (b)
Fig.7  Evolution of axial stress with time in Case A (a), Case B (b) and Case C (c) in the Satoh test
Fig.8  Schematic of feature point positions (a), and longitudinal stress formation of feature points P1 (b), P2 (c) and P3 (d) in the simulation results and their comparison with measurements
Fig.9  Distributions of welding residual stress at longitudinal (a) and transverse (b) directions
Fig.10  Comparison of simulation results and measurements of longitudinal (a) and transverse (b) residual stress
Fig.11  Distributions of welding residual stress at longitudinal (a) and transverse (b) directions with transverse constraint
Fig.12  Comparisons of simulation results of longitudinal (a) and transverse (b) residual stress in different constraint conditions
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