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Go to Editorial ManagerDue to the extremely complicated thermal cycle for the welding process, the fusion zone and heat-affected zone (HAZ) produce irreversible elastic-plastic deformation and residual stresses. The differential heating of the pipes caused by the weld heat source causes residual stress as a result of the welding process. However, the strength and lifetime of the component are also decreased as a result of residual stresses in and around the weld zone. The objective of this research is to analyze the residual stresses created during the welding process and select the best welding parameters that give the lowest residual stresses in 316SS pipes with 50 mm diameter and 4 mm thickness that were manually welded by used (316) welding wire and using shielded metal arc welding (SMAW) in a single-pass butt joint with the various values for each of current (58 , 68 , 78 , 88) amperes and voltage (22 , 23 , 24 , 25 , 26) volts. The shielded metal arc welding process involves heating, melting, and solidifying the parent metals and filler material in a localized fusion zone by a transient heat source to create a junction between the parent metals. The welding process free from preheating and heat treatment will be obtained. ANSYS Finite Element methods are used to calculate the welding residual stress distribution. The mechanical and thermal models were used to carry out the theoretical analysis. In general, the numerical study found that the residual stress distribution at the weld zone’s center is continuous, rising, and has a value of about (1738 MPa). Additionally, the residual stress at the boundary between the heat-affected zone and the weld zone climbs to a maximum value of around (3799 . 6 MPa). On the other hand, the magnitude of the residual stress in the heat-affected zone of the weld reduces significantly and achieves a minimum value at a position of (20 mm) with a value near zero.
The welding process involves a very complex thermal cycle, resulting in irreversible elastic-plastic deformation, and residual stresses in and around fusion zone and heat-affected zone (HAZ). A residual stress due to welding arises from the differential heating of the pipes due to the weld heat source. However, the presence of residual stresses in and around the weld zone reduces the strength and life of the component. The objective of this work is to measure the welding residual stress in ASTM (A-106 Gr. b) steel pipes with 4" diameter and 6 mm thickness welded manually (SMAW) in a three-pass butt joint. The shielded metal arc welding process consists of heating, melting, and solidification of parent metals and a filler material in a localized fusion zone by a transient heat source to form a joint between the parent metals. The welding process was carried out without preheating and heat treatment. This measurement of residual stress occurs by using the hole-drilling strain gauge method according to (ASTM E-873), and the experimental results for residual stresses obtained from welded carbon steel pipes are used to provide validation for finite element simulations. The welding process and welding residual stress distribution is calculated by Ansys Finite Element techniques. Theoretical considerations can be assessed by a mechanical model. Overall, there is good agreement between the predicted and measured distributions of residual stress, but the magnitude of predicted stress tends to be greater in the welding region.
AISI 4330 Low-alloy steel is good material for advanced application because of its properties including strength and longevity. However, performance may be modified with heat treatment procedures, include quenching and tempering. These processes can create residual stresses and retained austenite (RA), which have an effect on the metal's application. these factors influence fatigue life, dimensional stability, and fracture toughness of engineered components. uncontrolled residual stresses can reduce fatigue strength by up to 30%, while optimal retained austenite content (e.g., 5-10%) can enhance damage tolerance. This study focuses on residual stresses and retained austenite measurement in AISI 4330 low-alloy steel after heat treatment. including experimental and simulation methods. The review summarizes many scientific studies published between 2019 and 2024 and shows some main challenges. One challenge is the difference between experimental results (for example, from X-ray diffraction (XRD) and neutron (diffraction) and simulation results (especially using ANSYS software). Another challenge is that different methods for measuring retained austenite can give different results, which can change how we understand the steel's properties. The review also explains new progress in modeling heat treatment. This includes adding phase transformation models to finite element simulations. Future efforts should combine multiscale simulation, characterization, and machine learning to achieve predictive control over these properties in manufacturing.
In this paper, the Weibull uni-axial and multi-axial distribution function for polyethylene pips under pressure loading were developed and analyzed taking account of residual stress. Tensile test was achieved to determine mechanical properties and the Weibull parameters. Experimental method using the hole- drilling strain-gage method was used to measure the residual stresses in PE pipe and compare with that obtained from numerical finite element method (FEM). The obtained results show that there is a convergence between uni-axial and multi-axial distribution function, but multi-axial distribution function give large values compared to uni-axial distribution function. It was observed that the residual stresses have influence on failure assessment diagram and causes translation from elastic-plastic failure to brittle failure.
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec
In this paper, the influence of thermal residual stress on strength and fracture rotating speed of composite disc is studied and analyzed using finite difference method and laminated plate theory for two types of reinforced composite discs (radial fiber reinforced disc and circumferential fiber reinforced disc). As a result the thermal residual stress will reduce radial and tangential stresses in radial fiber reinforced disc, while it shall increase radial stresses and decrease tangential stresses in circumferential fiber reinforced disc. The existing of residual stresses in composite disc will leads to initiation of crack and begins to propagation near the inner diameter compared to case when neglecting residual stress for cases taken in analysis. It is also verified that the finite difference method is a good tool for stress analysis of composite disc under residual stress effec