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Experimental and finite element analysis of residual stress and distortion in GTA welding of modified 9Cr-1Mo steel

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Abstract

In this paper, investigation of residual stress and distortion induced in 3 mm thick Modified 9Cr-1Mo steel plates during GTA welding is carried out. SYSWELD software is used for the thermo-mechanical analysis. A 3D meshed model is created for the simulation and double ellipsoidal heat source distribution is used for the thermal analysis. Thermal cycles predicted near the fusion zone are compared with experimentally measured thermal cycles using thermocouples. Predicted residual stress profile across the fusion zone is compared with the measured profile using X-ray diffraction method. There is a good agreement between measured and predicted thermal cycles and residual stress profile. Distortion of the weld joint is measured using vertical electronic height gauge. Finite element analysis of distortion of the weld joint is carried out by applying both large and small distortion theories. Comparison of experimental and numerical results showed better accuracy if large distortion theory is applied.

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Author information

Authors and Affiliations

  1. Institute for Plasma Research, Gandhinagar, India

    Mohammed Zubairuddin & Vilas Chaudhari

  2. Indira Gandhi Centre for Atomic Research, Kalpakkam, India

    Shaju K. Albert, S. Mahadevan & M. Vasudevan

  3. Bhabha Atomic Research Centre, Mumbai, India

    V. K. Suri

Authors
  1. Mohammed Zubairuddin
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  2. Shaju K. Albert
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  3. S. Mahadevan
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  4. M. Vasudevan
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  5. Vilas Chaudhari
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  6. V. K. Suri
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Corresponding author

Correspondence to Mohammed Zubairuddin.

Additional information

Recommended by Associate Editor Young Whan Park

Mohammed Zubairuddin completed Master from NIT Rourkela in Machine Design and Analysis subject, currently doing his Ph.D. in Modified 9Cr-1Mo steel welding at Institute for Plasma Research Gandhinagar Gujarat India. His research includes Modeling and Finite element analysis of TIG welding, distortion, residual stress and phase transformation effect on residual stress.

Shaju K. Albert, Head, Materaials Technology Division, IGCAR is a metallurgist with 29 years of experience in the area of material joining. His research interests include welding metallurgy, weldability evaluation of materials, hardfacing, consumable development and repair welding. He has around 250 publications in peer reviewed journals, books and in proceedings of national and international conferences.

M. Vasudevan is Section head, Advanced Welding Processes and Modeling Section, Materials Technology Division, Indira Gandhi Centre for Atomic Research, Kalpakkam. He obtained his Ph.D. from Indian Institute of Technology, Chennai. He has published over 205 research papers in peer reviewed journals/books and conference proceedings.

S. Mahadevan is Program Leader, XRD Measurements Program in Nondestructive Evaluation Division of IGCAR. His research interests include characterization of microstructural changes in materials and estimation of residual stresses with X-ray diffraction. He has around 25 journal publications.

V. K. Suri is an outstanding scientist at Bhabha Atomic Research Centre Mumbai. He published more than 50 papers in Precision engineering. He is reviewer of more than 5 journals in Precision engineering area. He is a professor at HBNI DAE University at Mumbai and visiting faculty for IIT Bombay.

Vilas Chaudhri is a scientist at Institute for Plasma Research. He published more than 20 research papers in nuclear fusion area. He is working in fusion safety and remotely handling system area. He is Head for fusion safety and remote handling section for Indian TBM.

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Zubairuddin, M., Albert, S.K., Mahadevan, S. et al. Experimental and finite element analysis of residual stress and distortion in GTA welding of modified 9Cr-1Mo steel. J Mech Sci Technol 28, 5095–5105 (2014). https://doi.org/10.1007/s12206-014-1132-0

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  • DOI: https://doi.org/10.1007/s12206-014-1132-0

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