Analysis of circumferentially arc welded thin-walled cylinders to investigate the residual stress fields

The control of weld-induced imperfections like welding deformations and residual stresses is of critical importance in circumferentially welded thin-walled cylinders due to their wide utilization in high tech engineering applications in aerospace and aeronautical structures, pressure vessels and nuclear engineering fields. The paper presents a computational procedure for the analysis of temperature distributions and the subsequent residual stress fields during the course of arc welding of thin-walled cylinders of low carbon steel. Parametric studies based on numerical simulations are conducted to investigate the effects of critical welding process parameter on weld-induced residual stresses. Temperature-dependent thermo-mechanical behavior for low carbon steel, filler metal deposition along with double ellipsoidal heat source model is incorporated. The accuracy of the developed finite element simulation strategy is validated for transient temperature distributions and residual stress fields through full-scale shop floor welding experiments with proper instrumentation for data measurement. The aim is to present data to confirm the validity of in-process circumferential welding technology for thin-walled cylinders so that the in service failures of these structures due to process specific inherent stresses may be minimized.