Numerical simulation of residual stresses in hybrid welding for dissimilar girth welds of cast steel joints

Abstract

The study aimed to address the issue of elevated residual stress levels in dissimilar girth welds of cast steel joints. To achieve this, the hybrid welding technology, which yields high welding speeds while simultaneously reducing residual stresses, has been introduced. This study utilizes a numerical simulation method to investigate the temperature and residual stress field in the hybrid welding of G20Mn5 casting-Q355 low-alloy steel welded pipe. A comparison of the findings of this study with those of other welding processes revealed the technological advantages of hybrid welding. The research outcomes show that due to geometric discontinuities and material differences, the temperature field of the joint exhibits uneven distribution characteristics, and the peak temperatures on the Q355 steel side exceeds those on the G20Mn5 steel side. An evident stress gradient is present in the residual stress field of the joint post-welding, with peak stress located at the weld root on the Q355 steel. Compared with arc welding, the hybrid welding leads to decreased residual stresses and deformation, with high stress outside the heat-affected zone diminishing rapidly. Furthermore, it significantly improves the welding efficiency. This study elucidates the distribution and underlying causes of thermal and residual stress fields in dissimilar girth welds. This serves as a foundation for the application of hybrid welding technology in welded cast steel joints.

Keywords

hybrid welding / cast steel / dissimilar girth weld / residual stress / numerical simulation

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Funding

The SEU Innovation Capability Enhancement Plan for Doctoral Students(CXJH_SEU 24115)

Marine Economic Development Project of Guangdong Province(GDNRC [2022]25)