CHAPTER 2

LITERATURE REVIEW
2.1Introdution

One of the most widely used methods for joining metal in engineering is fusion
welding_The progress made in the chemical and oil industry, aerospace, shipbuilding,
structures and many others heavily relies on reliable welds. Potential losses and risk to
human life involved in weld failun: have resulted in stringent and welding process
control requirement.

Temperature history and residual stress in the welded structure depends upon the
properties of both base and weld metal, geometry of the weld groove, welding
parameters like current, voltage, speed, interpass temperature and preheat
temperature, Much work is carried out in past by many researchers to obtain the
solution for trainsent temperature, the temperature profile expirernentaIly and
numerical analysis during welding process and the weld induced residual stress. A
brief account of effort is presented here in.

2.2 Literature review on analytical solution for temperature

during welding pocess.
The first exact analytical solution of the heat flow during welding was obtained by
Rosenthal [3] in 1946. He had solved the heat conduction differential equation on
line, point and plane moving at constant speed with respect to fixed cartesian co-
ordinate system. For simplification he considercwd that the welding was performed
over a sufficient length so that the temperature distribution around the heat source
would nor change, This phenomenon is known as quasi ststionary or quasi steady
state.
Eger and Tsai [14] modified Rosenthal's model to include a 2-13 surface Gussian
distribution heat source and found analtical solution for the temperature of asemi-
infinite body subjected to moving heat source.
Nguyen et.al. [5] had developed, analytical solution for transient temperature filed of the semi-
Infinite body subjected to 3-D power density moving heat source. They had given integral form
Of the temperature field of the semi-infinite body subjected to 3-D power density moving heat
Source.

2.3 Literature review on Mathematical modeling of melting rate in twin-wire welding

D.Sc. Janez TusÏek (17 December 1999)

The paper treats four mathematical models for calculation of melting rate in arc fusion welding
with a wire in coil form. The mathematical models permit calculation of melting rate in direct
current welding with single-wire and double-wire electrodes (both polarities).
For single-wire welding the models treated have been improved with regard to the ones
published in the literature, for twin-wire welding, these are the first models for calculation of
melting rate. The mathematical models have already been tested in practice and the results
obtained show that they are very accurate, simple and applicable to practice.

A more elaborate mathematical model than the one existing before was developed for calculation
of melting rate in single-wire arc welding. Additionally a mathematical model for calculation of
melting rate in twin-wire arc welding not known from the literature before was developed.
On the basis of verification of validity of the mathematical models developed for single-wire
and twin-wire arc welding it can be stated that the models are quite a true representation
of the experimental results and that they are applicable to practical cases as well as to further
research work.

2.4 Literature review on Finite element modelling of a submerged arc welding

process
S.W. Wen, P. Hilton, D.C.J Farrugia (2001)
A multi-wire submerged arc welding (SAW) process has been modelled using a general purpose
finite element package ABAQUS. The paper explains briefly the welding process and its
application in thick wall linepipe manufacturing. Corresponding 2Dand 3D finite element (FE)
Models of the SAW process are presented. FE analyses were carried out to investigate the heat
transfer characteristic in the fusion and heat affected zones during welding.
The effect of process parameters and and welding geometry have been evaluated with and
without the consideration of residual stresses and strains induced from the forming processes
prior to welding. Comparison of FE predictions with experiment result are present where it is
appropriate. It is shown that the geometric distortion and residual stresses and strain caused by
welding can minimized through process optimization. It is therefore demonstrated that finite
element analysis can be applied to better understand the SAW process and hence be a useful tool
for future process development and control with the view of optimising product properties.

2.5 Literature review on Submerged arc welding of stainless steel and the challenge
from the laser welding process
N.A. McPherson, K. Chi, T.N. Baker (2003)

The welding of austenitic and duplex stainless steel has reassessed by questioning traditional
requirement of the weld metal and/or the heat affected zone(HAZ).The use of high dilution
submerged arc welding of austenitic and duplex stainless steels has been shown to produce
acceptable properties, despite the high heat input used in some instances.
Corrosion characteristics have been established as being acceptable too. These findings have
been further validated by examination of the weld region material using thin foil transmission
electron microcopy (TEM). This showed that while some intermetallic phases were present, they
did not adversely affected weld metal properties. In addition , an examination has taken place of
Nd:YAG laser –welded a ustenitic and duplex stainless steels, to establish the potential viability
of the route compared to the submerged arc welding process. The material properties, including
the relevant corrosion, including the relevant corrosion testing, have been found to be acceptable.
TEM has again shown that some intermetallic phase are present in the weld metal. It has been
suggested that a segregation mechanism is responsible for their presence in this case.
2.6 Literature review on Numerical modelling of welding

L.-E. Lindgren (6 August 2005)

There is a need to improve or even remove the need for heat input models in order to connect the
heat input into the finite element model with the actual welding parameters for different
processes. One possibility could be to combine thermo-mechanical models with fluid flow
models for the weld pool of the type used by Amberg and co-workers or DebRoy and co-
workers . Furthermore, models are needed for the specific heating process as in Zhu for a flame
or by Sudnik et al. for a laser.

2.1 Von Mises effective stress after welding and heat treatment

Hemmer et al. studied EB-welding of duplex stainless steels. They combined microstructure
models for austenite dissolution, subsequent grain growth in delta-ferrite and its decomposition
to austenite during cooling. The latter was assumed to be controlled by nitrogen diffusion in the
delta-ferrite. This was used to predict austenite depletion in the heat affected zone which can
reduce corrosion resistance and toughness. They used a simple model to predict weld penetration
and they had a cylindrical heat source in the numerical model that was calibrated by comparison
with measured temperatures. Myhr et al. developed a model for computing precipitate
distributions for simulation of welding and heat treatment of Al–Si–Mg alloys. Berglund et al.
used a simple microstructure model for austenite–martensite transformation of a martensitic
stainless steel in their welding simulations.

The modelling requirements for basic or standard analyses are quite established. However, there
will be a continuing need to improve material modelling and its coupling to the microstructure
evolution for more detailed analysis of the weld behaviour and pertaining questions about, for
example, cracking. The use of more physical based model for material behaviour and its relation
to the microstructure as well as evolution equations for the microstructure are expected to
improve the predictive capability in CWM.

2.7 Literature review on Effect of the welding heat input on residual stresses in butt-
welds of dissimilar pipe joints
D. Akbari, I. Sattari-Far (22 May 2008)

This study used finite element techniques to analyse the thermo-mechanical behaviour and
residual stresses in dissimilar butt-welded pipes. The residual stresses at the surface of some
weld specimenswere measured experimentally by using the hole-drilling method. The results of
the finite element analysis were compared with experimentally measured data to evaluate the
accuracy of the finite element modelling. Based on this study, a modelling procedure with
reasonable accuracy was developed. The developed finite element modelling was used to study
the effects of welding heat input on magnitude and distribution of welding residual stresses in
butt-welded pipes made of ferritic and austenitic steels. The hoop and axial residual stresses in
dissimilar pipe joints of 8 mm thick for V-groove shape were studied. It is shown that the
welding heat input has a significant effect on magnitude and distribution of residual stresses in
the stainless steel side of the studied joints.
This research employs the finite element method (FEM) to determine the residual stresses in
butt-welds of dissimilar pipe joints. The technique of element birth and death is used to simulate
the welding process. By the comparison with the experimental measurements, it has been shown
that the proposed computational procedure is an effective method for predicting the welding
residual stresses.

2.8 Literature review on Finite element modeling of welding processes

Andres Anca, Alberto Cardona , Jose Risso, Victor D. Fachinotti (6 May 2009)

This work deals with the simulation of fusion welding by the Finite Element Method. The
implemented models include a moving heat source, temperature dependence of thermophysical
properties, elasto-plasticity, non-steady state heat transfer, and mechanical analysis.The thermal
problem is assumed to be uncoupled from the mechanical one, so the thermal analysis is
performed separately and previously to the mechanical analysis at each time step. The
mechanical problem is based on the thermal history. A special treatment is performed on
mechanical elements during the liquid/solid and solid/liquid phase changes to account for stress
states. The three-dimensional stress state of a butt-welded joint is obtained as an example of an
application.

In the present article, finite element models have been used to analyze the thermal and
mechanical phenomena observed in welding processes. Thermal histories and residual stresses
have been predicted. The described methods provide a powerful means to optimize process
parameters off-line. The welding model can be used to predict and minimize deformations due to
changes in the weld sequence during the product development stage. A mathematical model was
implemented to represent the power density distribution of the external heat source. Results
obtained in this work using the heat source model are in close agreement with the original results
obtained by the experimental data of Christensen et al. A standard finite element formulation
limited to the solid domain has been adopted for the mechanical analysis, proving to be effective.
Regarding the material description, a standard model with isotropic hardening has proven to well
characterize the behavior of steel at high temperatures.
2.9 Literature review on Finite element analysis of the effect of welding heat input
and layer number on residual stress in repair welds for a stainless steel clad plate
W.C. Jiang , B.Y. Wanga, J.M. Gong b, S.T. Tu c (17 May 2010)

Stainless steel clad plate is widely used in petroleum, chemical and medicine industries due to its
good corrosion resistance and high strength. But cracks are often formed in clad layer during the
manufacture or service, which are often repaired by repair welding. In order to ensure the
structure integrity, the effects of residual stress need to be considered. The objective of this paper
is to estimate the residual stress and deformation in the repair weld of a stainless steel clad plate
by finite element method.
 Fig. 2.2. Finite element meshing of the repair model.

This study developed a sequential coupling finite element procedure to predict residual stresses
in a repair weld in a stainless steel clad plate. The effects of welding heat input and layer number
on residual stresses have been discussed. Based on the obtained results, the following
conclusions may be drawn:
(1) During the repair welding of the clad plate, large and nonuniform residual stresses are
generated in the repair weld and HAZ, which may have a great effect on structure integrity of the
repair structure.
(2) The welding heat input and layer number have great effect on residual stresses. They have no
significant effect on residual stress distribution law, but change the values of residualstresses.
(3) With the heat input increase, the transverse stress is decreased, while the longitudinal stress
changes little. The maximum residual stress is determined by the yield strength rather than heat
input.
(4) With the welding layer number increase, the residual stresses are decreased.
(5) Using multiple-layer welding and high heat input can be useful to decrease the residual stress
in repair weld of clad plate.

2.10 Literature review on Assessment of Heat Affected Zone of Submerged Arc

Welding Process through Digital Image Processing
Aniruddha Ghosha ,Somnath Chattopadhyayab ,R.K.Dasb,P.K.Sarkarb ( 2011)

Submerged arc welding (SAW) is a high quality, high deposition rate welding process commonly
used to join plates of higher thickness in load bearing components. This process of arc welding
provides a purer and cleaner high volume weldment that has relatively a higher material
deposition rate compared to the traditional welding methods. A common issue in the application
of SAW process raises a concern about the uncertainties involved with the heat affected zone
(HAZ) in and around the weldment. The most intriguing issue is about HAZ softening that
imparts some uncertainties in the welded quality. It increases the probability of fatigue failures at
the weakest zones caused by the heating and cooling cycle of the weld zone. An attempt has been
made in this paper to assess the heat affected zone of submerged arc welding of structural steel
plates through the analysis of the grain structure by means of digital image processing
techniques.

Fig.2.3Microstructure at the welded Fig.2.4 Transformed figure 1 for Figure 2.5 Complement image
zone of 50 Magnification further extraction of the features
of grain
The Heat Affected Zone related to submerged arc welding process is significantly less. The grain
growth are even lower than the 10% of the total area as observed by digital image processing
tool and that justifies the low level of heat affected zone of the process. The grains are
predominantly of smaller variety and the counts for larger grain are almost negligible. The
absence of larger size grains in the image vouch for the soundness of the weld in comparison to
the competing welding methodologies of structural steel plates.

2.11 Literature review on Effect of Heat input on Submerged Arc Welded Plates
Aniruddha Ghosha ,Somnath Chattopadhyayab ,R.K.Dasca (2011)

Deriving an analytical solution to predict the transient temperature distribution on the plate
during the process of Submerged Arc Welding (SAW). An analytical solution is derived from the
transient threedimensional heat conduction equation. The energy input that is applied on the plate
is taken as the volume of heat lost from the electric arc and the kinetic energy of filler droplets
specifically driven by gravity, electromagnetic force, arc drag force, carring mass, momentum
and thermal energy HAZ width calculation is also done with the help of the analytical solution of
the transient-three dimensional heat conduction equation. Analyses of micro-structural changes
are critically investigated to comprehend the HAZ softening and phenomena.

Predicted HAZ width(s)

SL. NO JOB NO. Predicted HAZ
width(mm)
1 A1 3.0
2 A2 3.2
3 A3 3.1
4 A4 3.5
5 B1 2.1
6 B2 1.9
7 B3 1.8
 8 B4 3.0

Validation of predicted data of HAZ width:

Fig.-:2.6 Hardness variation on different grid points as shown in fig.-8 for B4 Job (heat
input=2.84 kj/mm) of table No-1.

1. Heat distribution on welded plate is central Conicoidal shape for Submerged Arc Welding
process.
2. Transient temperature distribution on welded plate can be calculated with the help of Gaussian
Central Conicoidal Heat distribution technique.
3. HAZ width of a structural steel is in the region heated from 973K to the temperature just
below the melting temperature(i.e.1684K)
4. Existence of prominent grain growth provides the confirmatory evidence of the HAZ softening
phenomenon. In the welded portion, grain refinement occurs in most of the region due to the
heating and cooling cycle of SAW method. Predominant direction of the grain growth is clearly
observed from the photograph of the microstructure. This grain formation is distinctly revealed
in the magnification (50,100) for the heat input of 2.84 kj/mm. Hall Petch equation states the
strength of the metal is to vary reciprocally with size of subgrain.The similar phenomenon is also
revealed in case of hardness. In the context of this equation one can say that the hardness of the
grain growth portion will also manifest lower values related to higher grain sizes. In the grain
growth portion of the welded region longer grains have been found depicting the chances of
dislocation, slip, low yield strength and low hardness values measured in Rockwell scale B.