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Welding residual stresses are considered one of the most insidious forms of stresses which can affect integrity of structures. Residual stresses are difficult to measure physically and estimate theoretically. High tensile stresses can often lead to loss of performance in corrosion, fatigue and fracture. This paper presents development of a Finite Element Model using commercially available tool SYSWELD, to analyze the effect of changing filler configuration on the nature of welding residual stresses and distortion in S355J2G3 material. An S355J2G3 plate of 250x100x3mm dimensions is butt welded without filler and with ER70S6 filler. The results have been experimentally verified to validate the developed Finite Element Model. Blind hole drilling method is used for the measurement of residual stresses experimentally. The results indicate quite high tensile residual stresses developed in the molten zone for welding the plate without filler as compared to the case for welding with ER70S6 filler. A lesser distortion results when S355J2G3 plate is welded autogenously. The experimental & finite element analysis results show good agreement for the predicted residual stresses and distortion.

Muhammad Faisal Nadeem, Bilal Ahmed. (2019) Thermo-Mechanical Modelling and Experimental Verification of Distortion and Residual Stress for S355J2G3 Plate Welded by using Different Filler, Journal of Space Technology , Volume 9, Issue 1.
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