Three-dimensional finite element welding residual stress analysis of penetration nozzles: I – Sensitivity of analysis variables

•Penetration nozzles in nuclear reactors have J-groove welds.•Finite element welding residual stress analyses of penetration nozzles need 3-D analyses.•Sensitivity analysis for five variables related to 3-D FE welding residual stress analyses is performed.•Guidelines for 3-D FE welding residual stress analyses of penetration nozzles are provided.

This paper investigates effects of variables related to 3-D finite element welding residual stress analyses of penetration nozzles on residual stresses. Five variables are considered; (i) number of elements in the circumferential direction, (ii) number of beads in the circumferential direction, (iii) kinematic boundary conditions, (iv) circumferential modelling angle in 3-D finite element models and (v) detailed weld shape. Based on sensitivity analysis results, guidelines for 3-D finite element welding residual stress analyses of penetration nozzles are provided.