CHAPTER 1

1 INTRODUCTION
The arc welding process is common joining technology used in the manufacturing industry.
Despite this fact and general trend toward simulation based design of manufacturing processes and
products, the arc welding process has not been simulated accurately enough for many practical
process design needs. This partly due to the fact that the physical processes associated with the
electric arc it’s interaction with material are very phenomenon to understand from basic principles
four states (solid, liquid, gas and plasma) of several materials exits simultaneously in a small weld
volume and material interaction associated with electric, magnetic, kinetic, thermal, chemical,
atomic and fluidic processes take place. Many metallic structure in industries like nuclear reactor,
pressure vessel, boiler and other are asselembled by some kind of welding processes like shield
metal arc welding (SMAW), submerged arc welding (SAW), tungsten inert gas welding (TIG),
metal inert gas welding (MIG), etc.

Welding is very useful process for the manufacturing industry. Welding does large an upper edge
over the other metal joining process. However, the temperature history of weld components has a
strong influence on residual stresses, distortion and hence the fatigue behavior of welded
structures.
1.1 submerged arc welding process

Figure 1.1 schematic diagram of submerged arc welding

Process
 It is fusion process
 It may be automatic / semi automatic
 Arc create between consumable electrode and work piece
  Arc covered under granular flux
 Wire / electrode continuously fed to weld pool
 Wire / arc under flux moves along the groove
 Wire, BM &flux close to arc melt under flux

 On cooling weld metal solidifies

 Molten flux forms thick slag coating on weld

1.2 TYPICAL WELDING PARAMETER FOR SAW WELDING

Sr no. Wire Current Voltage Speed Dep. Wire and

A V mm/min Rate per flux
arc Hr
1 1.6 200-300 22-26 750-1500 3-4 kgs CS wire +
2 2 250-350 24-26 750-1250 3-4.5 kgs neutral flux

4 2.5 300-350 25-27 750-1250 4-4.5 kgs

5 3 400-500 28-30 500-100 5-5.5 kgs
6 4 550-650 30-32 400-750 5.5-7 kgs
7 5 600-800 30-34 350-700 6-8 kgs

1.2.1 Backing Requirement for Flux

 Spread the loose Flux in a Tray Of baking Oven

 Identify The Tray With The Quality/Grade Of Flux

 Bake Tray in an Oven Between 300° C to 350° C

 Baking Time 2Hrs to 3 Hrs

 Reduce the temperature to 100 ° C to 150 ° C

 Hold the Flux at this temperature till use

1.2.2 RESULTS IN CHANGE OF PARAMETERS

 Increase In Current

 More deposition, More Penetration, More BM Fusion

 Increase In Voltage

 More weld bead width, less penetration, less reinforcement, excess

spatter

 Increase In Travel Speed

 Decrease in Penetration, Decrease in Bead Width,

 Decrease In Gas Flow rate

 Results In porosity
  Long Stick Out / Electrode Extension

 Excess weld deposit with less arc intensity, poor bead finish,Shallow
Penetration

1.2.3 Application
Application cover pressure vessels, line pipe, storage tank, heavy structural, ships, railway
wagons and coaches, surfacing and build-up work.

1.3 influence of temperature history on evolution of microstructure

The energy input causes a thermal cycle that dries the grain and microstructure chages in
heat affected zone. The HAZ [ heat affected zone] ranges from solid-liqid transition zone
on its inner surface the unaffected base metal on its outer surface.

In addition hard and brittle materials can make the weld sensitive for stress and corrosion
and can also lead to the formation of stress induced cold cracks and pose danger in practice.
The thermal cycle in typical HAZ is shown in figure 1.2
 Figure 1.2 schematic representations of the transformation regions on the thermal
cycle

The microstructure computations are also fundamental to predicting the behaviour of the HAZ.
The HAZ is the most sensitive area if the weld joint in steel. The mechanical properites o the joint
depend on joint on austenite grain size and transformation products.

At a microscopic level, the metal physics can be described by scalar fields specifying the function
of each phase present, the composition of each phase and grain size of each phase at each point in
the heat-affected zone. In low alloy steels, the phase of greatest interest are ferrite, pearlite,
austenite, upper and lower bainite, martensite, carbite and liquid. Most steel used in welded
structure are produced with a ferrite-pearlite microstructure or a ferrite and austenite-martensite
constuent. When these steels are heated above Ae1, or the eutectoid temperature, the pearlite or
austenite-martensite constituent rapindly transforms to austenite with the same composition. The
austenite transfomaion in the different phase cooling at different as shown in figure 1.1 the
transformation is function of the temperature, time and the distance between high carbon regions.

1.4 influence of temperature history on residual stress

Residual stresses are stresses that remain in a component after any external loading or
forces are removed. Residual stresses can be viewed as a from of potential energy, and the
stress relieving, whether by thermal, peening, vibratory, long term storage or even by
unintentional “bumpy” transport, act as a means of release Of this potential energy. It has
been observed for many years that a workpiece that has been final machined can often
change shape during transport, outside of the final workpiece tolerances.

Residual stresses in metal structure occur for many reasons during the manufacturing
processes such as hot and cold working, rolling, bending, forging, casting machining
operation and the various welding processes. In welding, residual stresses result from
thermal strain during heating and cooling cycle of the weld metal and the adjacent heat
Affected zone (HAZ). They occur in al weldment zones and at microscopic levels they
develop due to thermal expansions and contraction and with volumetric changes associated
with phase transformation.

Since residual stresses can affect structural behavior, it is important to be able to predict
and model the residual stresses under different scenarios. The modeling of residual stresses.
The modeling of residual stresses is not an easy task as there are many different and often
complex variables involved:

 Material type.
 Material thicknesses and mass.
 Component configuration_
 Design and manufacturing process
Residual Stresses Related to Welding

Welding is one of the most common causes of significant residual stresses. The
cooler parent metal restrains contraction of the weld metal upon cooling leading to
inevitably large residual stresses.

Moreover, phase and volumetric changes at the microscopic level also contribute
to the residual stress phenomenon during welding. Being able to predict and
model residual stresses in different weldment configurations is important is
assessing the possibility of failure. Modeling of residual stresses is not a simple
task; there are many variables involved:

 Temperature.

 Time.

 Weld geometry.

 Thickness of material.

 Joint restraint.

 Weld sequences

 Heat input and cooling rates_

Residual stresses in welding occur owing to localised heating and there is an

abundance of non-uniform temperature profiles (ASM Volume 6 1983) Figur

1.3 shows a schematic representation of the changes in temperatures and stresses

during the welding process. Plane stresses are also shown implying the stresses

are uniformin the thickness direction.

Figure 1.3 schematic representation of change of temperature and stresses

 Figure 1.3 schematic representation of change of temperature and stresse

The residual stress pattern in Fig 1.2 occurs in materials of rather low thicknesses, in
thick plates there is a contraction stress at right angles to the plate surface and
consequently the stress field may intensify progressively as the joint is filled up with weld
deposits, The molten pool region is shown by the origin 0. Figure 1.2 (b) shows the
temperature profiles along different section with section B-B bisection the molten region
and section C-C being at a close distance from the weld pool as shown in section B-
B. Figure 1.2 (c) shows the residual stresses as a result of welding. Section A-A ahead of
the weld bead on the parent metal shows no residual stresses in the metal region
(section B-B) there are thermal stresses present but they are close to zero because molten
metal cannot support any loads. In the region away from the arc (transverse to the
direction of the welding) where cooling is occurring, the stresses are larger due to the
lower temperature and restrained condition. The maximum magnitudes of compressive
stresses and tensile stresses occurs at section D-D where the tensile stresses peak in the
cooled weld metal and compressive stresses peek in the surrounding parent weld metal.
This is more clearly shown in figure 1.2 (c). Where distribution of stresses in butt weld
joint can be seen. The tensile residual stresses present in the middle of the weld are very
close to yield point or in some case it is beyond the yield point of the parent material.

1.5 Effect of residual

It is well known that material response of structural component is

substantially affected by residual stress when subjected to the thermal and structural
loads. The magnitude of residual stress and deformation depends on the several factors
such as type of welding, welding procedure, object geometry, tack weld design and root
gap etc the effect of residual stresses present in bulk, may influence on the following:

 Reduction in fatigue and creep strength

 Stress corrosion cracking
  Brittle fracture
 Reduction in collapse strength

1.6 Need and scope of present work

Based on above discussion it can be concluded that though welding is
extensively used as permanent joining process in manufacturing, nuclear and chemical
industries, it has a number of detrimental effects on structural integrity and service
performance of the welded joints. These facts clearly indicate that welding phenomena
demands immediate attention and focus of researchers to improve product
quality and reliability. The optimized design reduces failure rate, improves product life
cycle, and important to all, the cost for re-welding/re-working can he major benefits
of this research.

The scope of the work in this dissertation is limited to single pass

butt welding of small thin plate of material (carbon steel) effect of welding speed, heat
input on the temperature profile during the welding is focused. Therefore a simulation
of heat source moving is develpoed based on finite element method (FEM).