welding metallurgy distortion residual stress . post ... library/20053429.pdf · -angular rotations...
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Welding Metallurgy
DistortionResidual Stress _.
&Post-Weld Heat
Treatment
Lecture 10
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Lecture Sc:ope
• Typical patt€!rns of distortion & residual stress inwelded assemblies
• Effects of residual stress
• Methods for prevention and correction ofdistortion
• Heat treatmemt of steel weldments
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Residual Stress: Definitions
• Residual stresses are the stresses that exist in a structurein the absence of external loads
• Residual stresses can be produced in metal structures bymany processes including: casting, heat treatmenf,forming and bending, and thermal cutting.
• Welding produces residual stress and distortion as aresult of localised heating and cooling of the work material
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Causes of Residual stress
• During welding, the weld and HAZ are heated totemperatures wf~1I above those of the surrounding material
• The weld and HAZ deform plastically because theirthermal expansion is resisted by the surrounding material
• As the weld cools and contracts, tensile stresses developelastically
• Welds contain tensile stresses that approach the yieldstress.
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Weld Thermal Strainsri
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3) The contraction is againresisted by the surroundingmaterial, leaving the weldand HAZ in a state oftension
l1) On heatin", thethennal strains areresisted by thesurrounding material,causing plasticdeformation
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Weld
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J2) On cooling, the weld Itand HAZ tend to contract
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Axial Residual Stress Pattern
The tensile stress in theweld is balanced bycompressive stresses oflower magnitude in thesurrounding plate
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t Axiall Stress
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Transverse Stresses in Butt Jointx
y y
tension compression
x
Axial stressDistribution of y-stresscomponent along x-x
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Pipe Girth Weld Displacements
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Tensile hoopstress
Displaced shape due tocircumferential shrinkagestrains (exaggerated)
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Typical Pipe Girth Weld Stresses
Longitudinal Stresses Circumferential St[esses60 60
20 e Outer Surface
e Inner Surface e Queer Surface
~ 0 e Inner Surface
-20
-40
-00 -<lO0 2 4 6 8 10 0 2 4 6 8 10
Distmce from weld CL (in) Distance from weld CL (in)
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Restraint Stresses
• When the workpiece is free to expand orcontract, residual stresses are confined to the region of thl~ weld
• When the workpiece is restrained, e.g.between rigid anchors, long-range reactionstresses develop
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Restraint Stresses
:-:supportreaction
Rigidsupport
RigidsUPP9rt
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supportreaction
Unwelded
Free
Restrained
Examples:• a short run of pipe welded between a rigidly mounted pump and a vessel• a beam welded between two stiff columns
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Effects of R.esidual Stress
• Residual stresses do not affect the loadcarrying capacity of ductile materials that failby yielding
• Residual stresses may promote failuremechanisms that are sensitive to localizedstresses-fatigue- brittle fracture- stress corrosion cracking- creep cracking
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Controll of Residual Stress
• Use minimum required weld size and heat input- J or U prE!parations give smaller weld areas
• Minimise constraint during welding
• Stress re lief- Heat treatment- Mechanical e.g. vibratory
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Distortion
• Distortion in welded fabrications is caused bymovements to accommodate thermal stresses
• Distortion in welded fabrications consists of:- transverse shrinkage-longitudinal shrinkage- angular rotations
• Distortion is CI problem mostly with thinnermaterials
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Bowing
Typical distortion pattern
(exaggera~~d) <~~~~kage_I I -0.1% of
I length _:,I Transverse...-t: ShrinkageI -1.5-3 mmIII
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AngularRotation-1_3°
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1. Angular Rotation
Fillet Weld Distortion
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~NeutraIAxi~'S~~2. Bending caused byweld shrinkage offsetfrom neutral axis ofsection
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r----··-··------··-·Peaking of Stiffened Panel
Examples: bridge deck, ship hull
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Control of distortion -1
1. Minimise heat input- Maximise melting efficiency, i.e. welding processes with high energy density
2. Use minimum required weld sizes,- e.g. intermittent rather than continuous fillet welds, J or U preparations
3. Balance welds about neutral axis- e.g. double V preparation, simultaneously weld top and bottom of plate girder
4. Use clamps, jigs & fixtures
5. Preset the workpiece to compensate for anticipatedchanges, for instance:
Fillet Welds
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Control of distortion -2
• Avoid using welding for precision assembly
• Machine to final dimensions after welding
...--__....ll,~«««<<<<<<~Fillet welds
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''machine bore to finaldimensions after welding
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Correction of distortion -1
• Flame Straightening
As welded [b.=====:J]Area or areas h~ed~----Jby gas torch to -6b~~OC~==========_~_
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Correction of distortion -2
• Mechanical straightening
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i::at Treatment of Welds
• Heat treatment is costly and should beavoided unless necessary for satisfactory performance
• May be required by applicable codes andstandards
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Weld HE~at Treatments
• Preheating- Heating prior to welding, usually to temperature~ less
than 200C- Applied in welding C-Mn steels to decrease cooling
rates and reduce HAZ hardness- 11.1 ....+ <'O"'''';",,,,,!I\I r""'1llirAr! fnr !':t~iolesssteels. nickel
alloys, titanium zirconium or aluminum
• Post Wield Heat Treatment- Heating after welding to relieve stresses, refine weld
grain structure, or improve weld properties
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Post Weld IHeat Treatment
• Definitions- Stress Relief
• Heating to a tl3mperature (usually around 600C) atwhich the yield strength is reduced such that residualstresses are relieved
- Normalizing• Heating to above the temperature for transformation to
austenite (A3) and slow cooling for to refine andhomogenize the grain structure
-Quenching• Heating as in normalizing and rapid cooling in water,
brine or air to develop high strength.
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--- ~---~-------------------,1--------Post WE~ld Heat Treatment
• Definitions (cont'd)- Tempering .
~ Reheating after quenching to below the transformationtemperature to reduce hardness and improve .ductility
- Solution Treating~ Heating to take into solution elements which will be
precipitated later in a controlled manner to producethe desired properties
-Ageing~ Reheslting after solution treating to allow formation of
preciplitates which strengthen the material.
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PWHT Methods
• Furnace Heating- Gas or electric most common- Restricted to parts that can be contained in a furnace- Optimum efficielncy and control
• Local Heatin~1
- Gas burners or electric resistance heaters most common- Mostly limited to relatively simple treatments, typically
stress relief of 8teel weldments- Main advantagl3 is capability to treat large or immovable
structures at low cost.
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PWHT Effects on Steels
- Stress reHef reduces residual stress and tempershardened heat affected zones. In most grades of steel(but not all) it improves ductility and toughness.
- Normalizing is used to refine the grain structure r~sulting
from welding when optimum properties are required, e.g.electrosla£1 welded pressure vessels
- Quench & Temper Some steels require Q&T treatmentsto develop high strength. Sometimes such steels can bewelded as··quenched followed by a combinedtemperlstr1ass relief treatment.
- The metallurgical aspects of welding Q&T steels must becarefully assessed.
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