Numerical Simulation of Temperature Evolution, Solid Phase Transformation, and Residual Stress Distribution during Multi-Pass Welding Process of EH36 Marine Steel
<p>The illustration of geometrical model.</p> "> Figure 2
<p>Microstructure morphology at several typical cooling rates (B: Bainite, F: Ferrite; P: Pearlite; M: Martensite).</p> "> Figure 3
<p>Continuous heating and cooling curves in the heat-affected zone of welding (SH-CCT).</p> "> Figure 4
<p>Microstructure evolution as a function of time at different welding energy densities: (<b>a</b>) 100 kJ/cm, and (<b>b</b>) 250 kJ/cm.</p> "> Figure 5
<p>Temperature field distribution during multi-pass welding process: (<b>a</b>) 250 s and (<b>b</b>) 350 s spatial distribution of temperature, and (<b>c</b>) temperature at different locations over time.</p> "> Figure 6
<p>Microstructure evolution at different locations: (<b>a</b>) P1, (<b>b</b>) P2, (<b>c</b>) P3, (<b>d</b>) P4, and (<b>e</b>) P5.</p> "> Figure 7
<p>Fraction of phases at different positions at the end of welding.</p> "> Figure 8
<p>Regulation of residual stress by multi-pass welding: the three-dimension residual stress evolution at multi-pass welding time periods of (<b>a</b>) 100 s, (<b>b</b>) 200 s, (<b>c</b>) 300 s, and (<b>d</b>) 400 s; (<b>e</b>) residual stress distribution in the vertical section of the heat-affected zone; (<b>f</b>) residual stress distribution on special line segments.</p> "> Figure 9
<p>Effect of multi-pass welding on material distortion: material at 400 s: (<b>a</b>) total distortion, (<b>b</b>) X-direction, (<b>c</b>) Y-direction, (<b>d</b>) Z-direction, and (<b>e</b>) distortion at positions P1 to P5 versus time.</p> "> Figure 10
<p>Effect of cooling rate on the impact toughness of multi-pass weldments under different temperatures: (<b>a</b>) impact energy at 253 K (−20 °C); (<b>b</b>) impact energy at 233 K (−40 °C).</p> ">
Abstract
:1. Introduction
2. Numerical Simulation and Experiment Methods
2.1. Establishment of Numerical Models
2.1.1. Temperature Field
2.1.2. Solid-State Phase Transformation
2.1.3. Residual Stress Field
2.2. Experimental Methods
- i.
- Specimens were heated to a peak temperature of 1300 K at a heating rate of 200 K/s, with a soaking duration of 1 s at peak temperature.
- ii.
- The heated specimen are initially cooled from 1300 K to 920 K within 4 s, corresponding to an approximate cooling rate of 100 K/s.
- iii.
- For the second cooling stage, the temperature was allowed to drop freely from 920 K to 200 K. To simulate a wide range of cooling conditions and capture various phase transformations, 12 distinct cooling rates were established, including 100 K/s, 75 K/s, 50 K/s, 25 K/s, 15 K/s, 8.5 K/s, 5 K/s, 3 K/s, 1.67 K/s, 1 K/s, 0.6 K/s, and 0.2 K/s.
- iv.
- Table 3 presents the cooling rates’ input into the simulation corresponding to various cooling times (t8/5). To align with the actual cooling rates, two-stage cooling rates were selected for input. At higher temperatures, a rapid cooling rate was designated. The heating and comparison data from the simulation experiment are presented in Table 3. The first cooling time is denoted as t1 with a cooling rate of V1; the second cooling time is t2 with a cooling rate of V2; and the total time is represented as t3.
3. Results and Discussions
3.1. Analysis of Thermal Simulation Results
3.2. Validation of the Phase Transformation Model
3.3. Temperature Field Distribution
3.4. Microstructure Distribution
3.5. Residual Stress and Deformation
3.6. Impact Performance Test of EH36 Steel
4. Conclusions
- Throughout the process of multi-pass fusion welding, the peak temperature values and the rate of heating/cooling in the area surrounding the heat source gradually decreases. The absorption of heat consistently reduces in the horizontal direction as the location moves away from the heat source, whereas a potential uptick may occur in the vertical direction owing to the additional heat supplied by subsequent welding passes.
- The specific parameters of the solid phase transformation model for EH36 steel were confirmed using the experimentally derived SH-CCT curve. Both numerical and experimental findings reveal that multi-pass welding promotes the transformation to bainite in the vicinity of the heat source. Concurrently, an increase in the proportion of acicular ferrite is observed with increasing distance from the welding fusion line in the horizontal plane.
- The residual stress evolution during the welding process of EH36 revealed that residual stresses are primarily concentrated at the interface between the weld and the heat-affected zone. Maximum residual stresses are predicted near the fusion line at the base of the model, while severe distortion occurs near the fusion line at the top of the model. Furthermore, multi-pass welding may alleviate the residual stress, particularly when coupled with the formation of acicular ferrite during cooling, which results in improved low-temperature impact toughness in areas distant from the heat source. Therefore, this model is intended to facilitate the systematic optimization of the multi-pass welding procedure in forthcoming applications to achieve a more favorable distribution of residual stresses and minimized distortion.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Temperature (K) | Density (kg/m3) | Thermal Conductivity (W/m·K) | Specific Heat (J/kg·K) | Poisson’s Ratio | Young’s Modulus (GPa) |
---|---|---|---|---|---|
298 | 7830 | 45.74 | 450 | 0.29 | 196.38 |
373 | 7810 | 45.88 | 480 | 0.293 | 191.06 |
473 | 7780 | 45.02 | 520 | 0.297 | 182.09 |
573 | 7740 | 43.16 | 560 | 0.301 | 172.98 |
673 | 7710 | 40.62 | 570 | 0.305 | 163.74 |
773 | 7670 | 37.79 | 580 | 0.308 | 154.36 |
873 | 7640 | 35.05 | 590 | 0.312 | 144.83 |
973 | 7600 | 32.37 | 600 | 0.318 | 137.74 |
1073 | 7580 | 29.66 | 605 | 0.327 | 125.86 |
1173 | 7542 | 27.77 | 610 | 0.346 | 115.47 |
1273 | 7505 | 28.98 | 630 | 0.352 | 105.45 |
1473 | 7430 | 31.38 | 660 | 0.364 | 85 |
1673 | 7320 | 33.8 | 690 | 0.376 | 59 |
1753 | 7250 | 34.61 | 1420 | - | - |
1773 | 7210 | 34.68 | 1120 | - | - |
1793 | 6980 | 33.74 | 820 | - | - |
3273 | 6980 | 33.74 | 820 | - | - |
Element | C | Si | Mn | N | Al | Ti | S | P | Nb | Fe |
---|---|---|---|---|---|---|---|---|---|---|
wt.% | 0.09 | 0.38 | 1.43 | 0.0024 | 0.029 | 0.014 | 0.003 | 0.014 | 0.025 | Rest |
Serial Number | t8/5 (s) | t1 (s) | V1 (K/s) | t2 (s) | V2 (K/s) | t3 (s) |
---|---|---|---|---|---|---|
1 | 3 | 4 | 100 | 7.2 | 100 | 11.2 |
2 | 4.5 | 4 | 100 | 10.6 | 75 | 14.6 |
3 | 6 | 4 | 100 | 14.4 | 50 | 18.4 |
4 | 12 | 4 | 100 | 29 | 25 | 33 |
5 | 20 | 4 | 100 | 48 | 15 | 52 |
6 | 35 | 4 | 100 | 85 | 8.5 | 89 |
7 | 60 | 4 | 100 | 144 | 5 | 148 |
8 | 100 | 4 | 100 | 240 | 3 | 244 |
9 | 180 | 4 | 100 | 431 | 1.67 | 435 |
10 | 300 | 4 | 100 | 720 | 1 | 724 |
11 | 500 | 4 | 100 | 1200 | 0.6 | 1204 |
12 | 1500 | 4 | 100 | 3600 | 0.2 | 3604 |
Phase Fraction (%) | Heat Input (100 kJ/cm) | Heat Input (250 kJ/cm) | ||
---|---|---|---|---|
Experiment | Simulation | Experiment | Simulation | |
Ferrite | 12.1 | 14.0 | 85.9 | 86.0 |
Pearlite | 0 | 0.5 | 14.1 | 11.9 |
Bainite | 87.9 | 82.4 | 0 | 2.1 |
Austenite | 0 | 3.1 | 0 | 0 |
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Wen, P.; Wang, J.; Jiao, Z.; Fu, K.; Li, L.; Guo, J. Numerical Simulation of Temperature Evolution, Solid Phase Transformation, and Residual Stress Distribution during Multi-Pass Welding Process of EH36 Marine Steel. Metals 2024, 14, 476. https://doi.org/10.3390/met14040476
Wen P, Wang J, Jiao Z, Fu K, Li L, Guo J. Numerical Simulation of Temperature Evolution, Solid Phase Transformation, and Residual Stress Distribution during Multi-Pass Welding Process of EH36 Marine Steel. Metals. 2024; 14(4):476. https://doi.org/10.3390/met14040476
Chicago/Turabian StyleWen, Pengyu, Jiaji Wang, Zhenbo Jiao, Kuijun Fu, Lili Li, and Jing Guo. 2024. "Numerical Simulation of Temperature Evolution, Solid Phase Transformation, and Residual Stress Distribution during Multi-Pass Welding Process of EH36 Marine Steel" Metals 14, no. 4: 476. https://doi.org/10.3390/met14040476