Computational Weld Mechanics – Towards a Simplified and Cost Effective Approach for Large Welded Structures

The current paper presents the development of a finite element analysis framework for computational weld mechanics, in order to carry out cost-effective predictions of welding induced residual stresses with good accuracy. Different approaches for describing the welding heat sources were investigated. The paper also investigates the influence of thermo-mechanical material properties of frequently used steel grades (S355–S960) on welding residual stresses and angular distortion. The predicted residual stresses were validated experimentally on several different small scale specimens with X-ray diffraction techniques. Finally, the developed simulation framework is demonstrated on complex welded structures in a construction equipment vehicle.