Numerical Simulation and Experimental Validation of Thermal Stresses in Welded Structures

Abstract

Welding is a critical process in various industries, but it often introduces thermal stresses that can compromise the structural integrity and performance of welded joints. This research paper presents a comprehensive study on the numerical simulation and experimental validation of thermal stresses in welded structures. A finite element model is developed to simulate the welding process, predicting temperature distributions, stress evolution, and distortion patterns. The accuracy of the numerical model is validated through experimental measurements using the hole-drilling method, where thermal stresses are measured in welded specimens and compared with the simulated results. The study identifies key factors influencing thermal stresses, such as material properties, welding parameters, and phase transformations. The results demonstrate good agreement between numerical predictions and experimental data, though some discrepancies highlight the need for further refinement of the simulation models. The findings provide valuable insights into optimizing welding processes to minimize residual stresses and enhance the durability of welded structures. This research contributes to advancing welding technology by integrating numerical and experimental approaches, offering a robust framework for analyzing and mitigating thermal stresses in welded joints.