Numerical Analysis of Residual Stress in Swing-Arc Narrow-Gap Gas Metal Arc Welding

In order to gain a deeper understanding of the distribution of residual stresses in swing-arc narrow-gap GMA welding, this paper comprehensively considers the arc motion trajectory and joint geometry and establishes a three-dimensional finite element numerical analysis model for residual stresses based on elastic–plastic theory. Using the Ansys software, the welding residual stresses were calculated under swing frequencies of 4 Hz, 3 Hz, and 2 Hz, and the distribution characteristics of residual stresses were analyzed. The results indicate that the model effectively and accurately represents the movement trajectory and distribution characteristics of the swing arc. Furthermore, the calculated temperature field and residual stress outcomes align closely with the experimental findings, thereby validating the accuracy of the model. Under varying swing frequencies, the distribution patterns of residual stress along each sampling line exhibit a consistent similarity. The residual stress is predominantly concentrated in the weld zone and the adjacent heat-affected zone, while it remains relatively low in areas further away from the weld. As the swing frequency increases, the residual stress decreases. The reason for this is that an increase in swing frequency can lead to a more uniform distribution of arc heat within the weld bead, ultimately resulting in lower residual stress. © 2025 by the authors.