PSI - Issue 47

ScienceDirect Structural Integrity Procedia 00 (2022) 000 – 000 Structural Integrity Procedia 00 (2022) 000 – 000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 47 (2023) 892–900

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF27 chairpersons Abstract Non-uniform temperature gradients are induced in welded structures causing rapid thermal expansion-contraction and generating residual stresses and deformations. These latter are generally measured by means of experimental techniques that have limited accuracy and high costs for large structures. To circumvent these issues, the numerical simulation is proposed in the present investigation to explicitly simulate the weld filler formation during the process, thus allowing to compute the fields of temperature during the process. The simulation is based on FEM and birth-and-death procedure and is applied to the example case of a Manual Metal Arc Welding two-passes butt-welded joint made of a low carbon steel. Numerical results are compared with experimental data available in literature showing an acceptable correlation on temperature levels during welding. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF27 chairpersons Keywords: Finite Element Method (FEM); Manual Metal Arc Welding (MMAW); birth and death; distortions; residual stresses; butt joint; simulation 1. Introduction Welding is one of the most common joining techniques in industry thanks to its well-known advantages as costs and weight savings, high performances of welded structures and flexibility during the designing process. Several welding techniques have been developed along the years (Astarita et al. (2021); Mehta et al. (2021)) and, nowadays, their advancing is still of great interest for many industrial sectors. Most of the last developments (Boccarusso et al. (2017); Rubino et al. (2020a-b); Meneghetti et al. (2017a-b)) are aimed to improve the welding processes, 27th International Conference on Fracture and Structural Integrity (IGF27) FEM simulation of the welding process of a butt-welded joint and comparison with experimental data V. Giannella a,* , A. Califano a , A. Bacco a , F. Berto b , R. Sepe a a Dept. of Industrial Engineering, University of Salerno, 84084 Fisciano, Italy b Dept. of Chemical Materials Environment Engineering, Sapienza University, 00184 Rome, Italy Abstract Non-uniform temperature gradients are induced in welded structures causing rapid thermal expansion-contraction and generating residual stresses and deformations. These latter are generally measured by means of experimental techniques that have limited accuracy and high costs for large structures. To circumvent these issues, the numerical simulation is proposed in the present investigation to explicitly simulate the weld filler formation during the process, thus allowing to compute the fields of temperature during the process. The simulation is based on FEM and birth-and-death procedure and is applied to the example case of a Manual Metal Arc Welding two-passes butt-welded joint made of a low carbon steel. Numerical results are compared with experimental data available in literature showing an acceptable correlation on temperature levels during welding. © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF27 chairpersons Keywords: Finite Element Method (FEM); Manual Metal Arc Welding (MMAW); birth and death; distortions; residual stresses; butt joint; simulation 1. Introduction Welding is one of the most common joining techniques in industry thanks to its well-known advantages as costs and weight savings, high performances of welded structures and flexibility during the designing process. Several welding techniques have been developed along the years (Astarita et al. (2021); Mehta et al. (2021)) and, nowadays, their advancing is still of great interest for many industrial sectors. Most of the last developments (Boccarusso et al. (2017); Rubino et al. (2020a-b); Meneghetti et al. (2017a-b)) are aimed to improve the welding processes, 27th International Conference on Fracture and Structural Integrity (IGF27) FEM simulation of the welding process of a butt-welded joint and comparison with experimental data V. Giannella a,* , A. Califano a , A. Bacco a , F. Berto b , R. Sepe a a Dept. of Industrial Engineering, University of Salerno, 84084 Fisciano, Italy b Dept. of Chemical Materials Environment Engineering, Sapienza University, 00184 Rome, Italy

* Corresponding author. E-mail address: vgiannella@unisa.it * Corresponding author. E-mail address: vgiannella@unisa.it

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF27 chairpersons 2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF27 chairpersons

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF27 chairpersons 10.1016/j.prostr.2023.07.029