Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

Stershic, Andrew J.; D’Elia, Christopher R.; Beghini, Lauren L.; Hill, Michael R.; Clausen, Bjørn; Balch, Dorian K.; Maguire, Michael; San Marchi, Christopher W.; Foulk III, James W.; Hanson, Alexander A.; Manktelow, Kevin L.

doi:10.1016/j.ijsolstr.2024.113112

Title: Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

Journal Article · 24 October 2024 · International Journal of Solids and Structures

DOI: https://doi.org/10.1016/j.ijsolstr.2024.113112 · OSTI ID:2477551

^[1];

^[2]; Beghini, Lauren L. ^[1];

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^[3];

^[1]; Maguire, Michael ^[1];

^[1];

^[1]; Hanson, Alexander A. ^[1];

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Sandia National Laboratories (SNL-CA), Livermore, CA (United States)
Univ. of California, Davis, CA (United States)
Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)

Welding processes used in the production of pressure vessels impart residual stresses in the manufactured component. Computational modeling is critical to predicting these residual stress fields and understanding how they interact with notches and flaws to impact pressure vessel durability. Here, in this work, we present a finite element model for a resistance forge weld and validate it using laboratory measurements. Extensive microstructural changes, near-melt temperatures, and large localized deformations along the weld interface pose significant challenges to Lagrangian finite element modeling. The proposed modeling approach overcomes these roadblocks in order to provide a high-fidelity simulation that can predict the residual stress state in the manufactured pressure vessel; a rich microstructural constitutive model accounts for material recrystallization dynamics, a frictional-to-tied contact model is coordinated with the constitutive model to represent interfacial bonding, and adaptive remeshing is employed to alleviate severe mesh distortion. An interrupted-weld approach is applied to the simulation to facilitate comparison to displacement measures. Several techniques are employed for residual stress measurement in order to validate the finite element model: neutron diffraction, the contour method, and the slitting method. Model-measurement comparisons are supplemented with detailed simulations that reflect the configurations of the residual-stress measurement processes themselves. The model results show general agreement with experimental measurements, and we observe some similarities in the features around the weld region. Factors that contribute to model-measurement differences are identified. Finally, we conclude with some discussion of the model development and residual stress measurement strategies, including how to best leverage the efforts put forth here for other weld problems.

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Research Organization:: Sandia National Laboratories (SNL-CA), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA), Office of Defense Programs (DP)

Grant/Contract Number:: NA0003525; 89233218CNA000001

OSTI ID:: 2477551

Report Number(s):: SAND--2024-15456J

Journal Information:: International Journal of Solids and Structures, Journal Name: International Journal of Solids and Structures Journal Issue: 1 Vol. 306; ISSN 0020-7683

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
42 ENGINEERING
Contour method
Finite element analysis
Residual stress
Resistance forge weld
Validation

Title: Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

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References (33)

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