Physically-based constitutive modelling of residual stress development in welding of aluminium alloy 2024
- Department of Engineering, University of Cambridge, Trumpington St., Cambridge, CB2 1PZ (United Kingdom)
- Manchester Materials Science Centre, University of Manchester and UMIST, Grosvenor St., Manchester, M1 7HS (United Kingdom)
- TWI, Granta Park, Cambridge, CB1 6AL (United Kingdom)
A finite element model has been developed to predict the evolution of residual stress and distortion which takes into account the history-dependence of the yield stress-temperature response of heat-treatable aluminium alloys during welding. The model was applied to TIG welding of 2024-T3 aluminium alloy, and the residual strain predictions validated using high resolution X-ray synchrotron diffraction. The goal was to capture the influence of the permanent evolution of the microstructure during the thermal cycle with a straightforward numerical procedure, while retaining a sound physical basis. Hardness and resistivity measurements after isothermal hold-and-quench experiments were used to identify salient temperatures for zero, partial and full dissolution of the initial hardening precipitates, and the extent of softening - both immediately after welding, and after natural ageing. Based on these data, a numerical procedure for weld modelling was proposed for tracking the different yield responses during heating and cooling based on the peak temperature reached locally. This history-dependent model was superior to a conventional model in predicting the peak tensile strains, but otherwise the effect of temperature history was weak for 2024-T3. Predictions of the hardness profile immediately after welding compared with the post-weld naturally aged hardness provided insight into the competition between dissolution and coarsening of the precipitates in the heat-affected zone.
- OSTI ID:
- 20634780
- Journal Information:
- Acta Materialia, Vol. 52, Issue 17; Other Information: DOI: 10.1016/j.actamat.2004.06.048; PII: S1359-6454(04)00363-5; Copyright (c) 2004 Elsevier Science B.V., Amsterdam, The Netherlands, All rights reserved; Country of input: International Atomic Energy Agency (IAEA); ISSN 1359-6454
- Country of Publication:
- United States
- Language:
- English
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