PSI - Issue 79

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ScienceDirect

Procedia Structural Integrity 79 (2026) 335–341

28th International Conference on Fracture and Structural Integrity - 3rd Mediterranean Conference on Fracture and Structural Integrity Numerical analysis of residual stresses in dissimilar welded joint

A. Bacco a, *, A. Califano a,b , A. Greco a , R. Sepe a a Dept. of Industrial Engineering, University of Salerno, 84084, Fisciano, Italy b Dept. of Industrial Engineering, University of Naples Federico II, 80125, Napoli, Italy

© 2025 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 IGF28 - MedFract3 organizers Keywords: Dissimilar welding, FCAW, Hybrid joint, Steel, Cast-iron, S355, GJS500-7, Numerical simulation, FEM, Birth and death method, residual stresses. Abstract Joining two dissimilar materials is one of the most innovative challenges in the field of welding. It is therefore important to study the manufacturability of such joints with the aim of minimizing the invasiveness, in terms of residual stress and deformation, of the welding process on the base materials. Welding parameters, preheating temperatures, and the number of passes can have a considerable effect on the integrity and final strength of the joint. The use of the Finite Element Method (FEM) to simulate thermo mechanical behaviour during welding allows the evaluation of heat input and thermal gradients, thus providing information on the development of residual stresses and deformations during the welding and cooling phases. This study investigates the distributions of residual stresses induced by the welding process in dissimilar cast iron-steel butt joint using a finite element model to simulate its thermo-mechanical behaviour. The findings of this work provide a preliminary reference for future studies involving the use of this type of dissimilar joint.

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

2452-3216 © 2025 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 IGF28 - MedFract3 organizers 10.1016/j.prostr.2025.12.342