Three-dimensional finite element analysis to predict the effects of SAW process parameters on temperature distribution and angular distortions in single-pass butt joints with top and bottom reinforcements

Achieving adequate top and bottom reinforcement is important to minimize angular distortions in single-pass submerged arc welded (SAW) butt joints. This is achieved in the present work by using a reusable flux-filled backing strip and proper SAW process parameters without resorting to costly distortion mitigation techniques. The butt joints were made without edge (square butts) preparation. The process was also modeled by using three-dimensional finite element analysis by incorporating the top and bottom reinforcements into the modeling. Filler material deposition was also simulated. Temperature distributions and angular distortions obtained from the modeling closely matched with the experimental values. Thus, the cost effective experimental methodology established in the present work can be utilized for minimizing angular distortions in SAW square butts. The modeling methodology adopted can be used for predicting the angular distortions in SAW square butts with top and bottom reinforcements.