Numerical Simulation and Development of Efficient Calculation Method for Residual Stress of SUS316 Saddle Tube-Pipe Joint

doi:10.11900/0412.1961.2021.00460

Acta Metall Sin

2022, Vol. 58

Issue (10): 1334-1348 DOI: 10.11900/0412.1961.2021.00460

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Numerical Simulation and Development of Efficient Calculation Method for Residual Stress of SUS316 Saddle Tube-Pipe Joint

LUO Wenze, HU Long, DENG Dean(

)

College of Materials Science and Engineering, Chongqing University, Chongqing 400045, China

Cite this article:

LUO Wenze, HU Long, DENG Dean. Numerical Simulation and Development of Efficient Calculation Method for Residual Stress of SUS316 Saddle Tube-Pipe Joint. Acta Metall Sin, 2022, 58(10): 1334-1348.

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Abstract

A thick-walled SUS316 saddle tube-pipe welded joint is used in nuclear power equipment. A very long computing time and huge memory space are needed to simulate welding residual stress when the thermo-elastic-plastic finite element method is used because of the complex shapes, large sizes, and many weld passes of this joint. To solve the computational problem, two efficient and accurate computational approaches were proposed based on MSC. Marc finite element software platform. In the first computational approach, the finite element model of the SUS316 saddle tube-pipe welded joint was established with the same dimensions as the actual joint. Two heat sources were used to balance the computing time and calculation precision. The moving heat-source model was used to simulate the heat input for the backing and cover passes. In contrast, the instantaneous heat-source model was employed to consider the heat input for the other passes. Considering the geometric symmetry, a quarter model was developed in the second computational approach, and the instantaneous heat-source model was used to model the heat input for all passes. In the material model, both work hardening isotropic rule and annealing effect were considered because SUS316 is sensitive to work hardening. The simulation results of the thermal cycle during the welding process and residual stress distribution in and near the fusion zone were compared using the measured data. The results of thermal cycles and the residual stress distributions obtained using two computational approaches matched the experimental measurements. When the first computational approach was used, not only the residual stress distribution in the whole welded joints could be obtained, but also the features of residual stress distribution near the weld start-end location were able to capture. The second computational approach could predict the magnitude and distribution of residual stress in the stable range of the joint and could save computing time and huge memory space. Thus, the second computational approach is useful for practical engineering applications.

Key words: SUS316 stainless steel tube-pipe welded joint saddle weld welding residual stress symmetry model efficient calculation approach

Received: 26 October 2021

ZTFLH:

TG404

Fund: National Natural Science Foundation of China(51875063)

About author: DENG Dean, professor, Tel: (023)65102079, E-mail: deandeng@cqu.edu.cn

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	Wenze LUO
	Long HU
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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00460 OR https://www.ams.org.cn/EN/Y2022/V58/I10/1334

Fig.1 Photographs of a vice-tube (a), a circular pipe (b), and a saddle tube-pipe joint (c), the dimension diagram of the tube-pipe welded joint (unit: mm) (d)

Table 1 Chemical compositions of SUS316 base metal and Y316L welding wire

Fig.2 Schematic of an arrangement of weld passes and locations of thermo-couples

Table 2 Welding speed, heat input, and arc efficiency of each bead

Fig.3 Schematics of strain gauge locations in top view (a), and strain gauge locations in 90° and 180° cross-section (b)

Fig.4 Schematic finite element models of full size model (Model 1) (a) and a quarter model (Model 2) (b)

Fig.5 Arrangement of weld beads in the finite element models

Table 3 Parameters in the isotropic strain-hardening model for SUS316 stainless steel^[24]

Fig.6 Comparison between simulated and experimental results for the welding temperature as a function of time
(a) the 1st pass (the measurement locations at points A and B (inset))
(b) the 46th pass (the measurement locations at points C and D (inset))

Fig.7 Schematic showing the transformation from the coordinate to cylindrical coordinate for the residual stress (r—direction of transverse residual stress, θ—direction of longitudinal residual stress, z₁—the axial direction)

Fig.8 Overall hoop residual stress distributions after welding for Model 1 (a) and Model 2 (b)

Fig.9 Hoop residual stress distributions in the characteristic cross-sections for Model 1
(a) 0° (b) 90° (c) 180° (d) 270°

Fig.10 Hoop residual stress distributions in the characteristic cross-sections for Model 2
(a) 90° (b) 180°

Fig.11 Experimental and numerical results of the hoop residual stress in 90° cross-section, located at line 1 (a) and line 2 (b) (Insets show the measuring directions)

Fig.12 Experimental and numerical results of the hoop residual stress in 180° cross-section, located at line 3 (a) and line 4 (b) (Insets show the measuring directions)

Fig.13 Hoop residual stress distributions along the welding centerline in 90° section after welding at different layers (Inset shows the measuring direction)

Fig.14 Overall radial residual stress distributions for Model 1 (a) and Model 2 (b)

Fig.15 Radial residual stress distributions in the characteristic cross-sections for Model 1
(a) 0° (b) 90° (c) 180° (d) 270°

Fig.16 Radial residual stress distributions in 90° (a) and 180° (b) cross-sections for Model 2

Fig.17 Experimental and numerical results of radial residual stress in 90° cross-section, located at line 1 (a) and line 2 (b) (Insets show the measuring directions)

Fig.18 Experimental and numerical results of radial residual stress in 180° cross-section, located at line 3 (a) and line 4 (b) (Insets show the measuring directions)

Fig.19 Radial residual stress distributions along the welding centerline in 90° section after welding different layers (Inset shows the measuring direction)

Fig.20 Schematics of SUS316 Von Mises yield surface in the triaxial stress state (a) and the Von Mises yield surface expansion in the biaxial stress state (b) (σ₁—major principal stress, σ₂—second principal stress, σ₃—third principal stress, σ_s—yield strength, σ $s'$ —yield strength after work hardening)

Fig.21 Equivalent Von Mises stress distributions in 90° cross-section for Model 1

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