Using finite element and ultrasonic method to evaluate welding longitudinal residual stress through the thickness in austenitic stainless steel plates

This paper uses a 3D thermo-mechanical finite element analysis to evaluate welding residual stresses in austenitic stainless steel plates of AISI 304L. The finite element model has been verified by the hole drilling method. The validated finite element (FE) model is then compared with the ultrasonic stress measurement based on acoustoelasticity. This technique uses longitudinal critically refracted (LCR) waves that travel parallel to the surface within an effective depth. The residual stresses through the thickness of plates are evaluated by four different series (1 MHz, 2 MHz, 4 MHz and 5 MHz) of transducers. By combining FE and LCR method (known as FELCR method) a 3D distribution of residual stress for the entire of the welded plate is presented. To find the acoustoelastic constant of the heat affected zone (HAZ), a metallographic investigation is done to reproduce HAZ microstructure in a tensile test sample. It has been shown that the residual stresses through the thickness of stainless steel plates can be evaluated by FELCR method.

► The main goal is ultrasonic evaluation of through thickness stresses.
► Welding process of a stainless steel plate is modeled by finite element analysis.
► The acoustoelastic constant of the HAZ is directly measured.
► Residual stresses are measured by four different series of ultrasonic transducers.
► The comparison between ultrasonic and FE results show an acceptable agreement.