Welding distortion analysis of multipass joint combination with different sequences using 3D FEM and experiment

• 3D FEM was used to analyze the welding distortion on two different sequences.
• Simulation results were validated with experiments using automated welding system.
• Simulation results and experiments showed acceptable accuracy.
• Welding sequence “outside–inside” showed less distortion than “inside–outside”.

This paper presents an investigation of the welding sequence effect on induced angular distortion using FEM and experiments. The specimen of a combined joint geometry was modeled and simulated using Multipass Welding Advisor (MWA) in SYSWELD 2010 based on the thermal-elastic-plastic approach with low manganese carbon steel S3355J2G3 as specimen material and Goldak's double ellipsoid as heat source model. To validate the simulation results, a series of experiments was conducted with two different welding sequences using automated welding process, low carbon steel as parent metal, digital GMAW power source with premixed shielding gas and both-sided clamping technique. Based on the results, it was established that the thermo-elastic-plastic 3D FEM analysis shows good agreement with experimental results and the welding sequence “from outside to inside” induced less angular distortion compared to “from inside to outside”.