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Title: Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach

Abstract

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three-dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.

Authors:
ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1];  [2];  [3];  [4];  [4]
  1. ORNL
  2. General Motors (GM) Corporation, R&D
  3. General Motors (GM) Corporation
  4. Electric Power Research Institute (EPRI)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1468221
DOE Contract Number:  
AC05-00OR22725
Resource Type:
Conference
Resource Relation:
Conference: ASME 2018 Pressure Vessels and Piping Conference (PVP 2018) - Prague, , Czech Republic - 7/15/2018 12:00:00 PM-7/20/2018 12:00:00 PM
Country of Publication:
United States
Language:
English

Citation Formats

Huang, Hui, Chen, Jian, Feng, Zhili, Carlson, Blair, Wang, Huiping, Frederick, Greg, and Crooker, Paul. Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach. United States: N. p., 2018. Web.
Huang, Hui, Chen, Jian, Feng, Zhili, Carlson, Blair, Wang, Huiping, Frederick, Greg, & Crooker, Paul. Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach. United States.
Huang, Hui, Chen, Jian, Feng, Zhili, Carlson, Blair, Wang, Huiping, Frederick, Greg, and Crooker, Paul. Sun . "Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach". United States. https://www.osti.gov/servlets/purl/1468221.
@article{osti_1468221,
title = {Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach},
author = {Huang, Hui and Chen, Jian and Feng, Zhili and Carlson, Blair and Wang, Huiping and Frederick, Greg and Crooker, Paul},
abstractNote = {Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three-dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2018},
month = {7}
}

Conference:
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