Formation mechanism and evolution of welding residual stress in thick plate T-joint
Article Text (Baidu Translation)
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摘要: 为明确厚板T型接头焊接过程中残余应力的形成机制及其分布特征，通过开展现场T型接头焊接试验，测量了各焊道的应变变化曲线、热循环曲线和熔敷尺寸，并结合ABAQUS有限元软件模拟，采用生死单元技术模拟了多道焊焊接过程，计算了焊接温度场、热变形和残余应力的空间分布；根据试验与数值模拟的结果，结合已有焊接残余应力理论，研究了厚板T型接头焊接残余应力的形成机理；取T型接头中部截面及特定路径分析了焊接残余应力的演变过程及分布情况。研究结果表明：在焊接过程中，模拟与试验结果的热循环曲线均呈现阶梯式上升，母材的热变形表现出周期性变化；焊缝区域分布的残余应力以三向受拉为主，焊缝纵向残余应力分量最大值可达915 MPa，随着焊道层数的增加，拉应力峰值逐渐升高，且其分布位置随焊道层数的增加向外扩展，而热影响区内的母材则主要承受压应力；沿板厚方向，纵向及横向的残余应力分量均呈现出“C”形分布特征，残余应力的分布面积和峰值同样随焊道层数的增加而增大，最大可达486 MPa；压缩残余塑性应变为焊接残余应力形成的主因，对于厚板的多层多道焊，外层焊道对内层焊道的回火效应以及总体的焊接顺序显著影响了其焊接残余应力形成过程与最终分布。Abstract: To clarify the formation mechanism and distribution characteristics of residual stress during the welding process of thick plate T-joint, welding tests of T-joints were conducted on-site. Strain variation curves, thermal cycle curves, and deposition sizes of each weld pass were measured. Along with the ABAQUS finite element software used for simulations, the element birth and death technique was employed to simulate the multi-pass welding process. The welding temperature field, thermal deformation, and spatial distribution of residual stress were calculated. Based on the test and numerical simulation results, combined with existing theories of welding residual stress, the formation mechanism of welding residual stress in thick plate T-joint was studied. The central cross-section of the T-joint and specific paths were selected to analyze the evolution and distribution of welding residual stress. The results show that the thermal cycle curves from both simulations and experiments show a stepwise increase, and the thermal deformation of the base metal exhibits periodic changes. The residual stress in the weld region is mainly tensile in three directions. The maximum longitudinal residual stress in the weld reaches 915 MPa. As the number of weld passes increases, the peak tensile stress rises, with its distribution position shifting outward. The base metal in the heat-affected zone mainly bears compressive stress. Along the plate thickness direction, the longitudinal and transverse residual stress components show a C-shaped distribution. The distribution area and peak value of residual stress also increase with the number of weld passes, reaching a maximum of 486 MPa. Compressive residual plastic strain is the main cause of welding residual stress. For multi-layer and multi-pass welding of thick plates, the tempering effect of the outer weld passes on the inner ones, as well as the overall welding sequence, significantly affects the formation process and final distribution of the welding residual stress.
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图 1 节点板-上弦杆顶板T形接头与接头焊缝坡口
Figure 1. Gusset plate-top chord T-joint and joint weld groove
图 8 模拟与试验的部分道焊熔池对比
Figure 8. Comparison of simulated and experimental partial weld pools
图 9 温度测点在前4层焊道内的热循环曲线
Figure 9. Thermal cycle curves of temperature measuring point in the first four layers of passes
图 11 第4道焊热源在经过测点时的时间-应变曲线
Figure 11. Time-strain curves of the fourth welding heat source when passing through the measuring point
图 12 热源经过时应变测点处的母材变形过程
Figure 12. Deformation process of base metal at strain measuring point when heat source passes through
图 14 以压缩塑性应变为主因的残余应力产生过程
Figure 14. Residual stress generation process dominated by compressive plastic strain
图 15 T型接头中部截面4个阶段的残余应力分布云图
Figure 15. Cloud graphs of residual stress distribution in four stages of the central cross-section of T-joint
表 1 Q500qE钢化学成分表(质量分数)
Table 1. Chemical composition of Q500qE steel (mass fraction)
化学成分 C Si Mn P S Ni Nb Cr Cu Pcm 质量分数/% 0.05 0.25 1.59 0.012 0.001 5 0.32 0.025 0.18 0.02 0.17 
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表 2 焊缝各层焊道数量
Table 2. Number of passes of each layer of weld
层数 1 2 3 4 5 6 7 8 焊道数 1 2 3 4 4 5 5 6
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