Finite element modelling of a submerged arc welding process

A multi-wire submerged arc welding (SAW) process has been modelled using a general purpose finite element package ABAQUS. The paper explains briefly the welding process and its application in thick wall linepipe manufacturing. Corresponding 2D and 3D finite element (FE) models of the SAW process are presented. FE analyses were carried out to investigate the heat transfer characteristics in the fusion and heat affected zones during welding. The effect of process parameters and weldment geometry have been evaluated with and without the consideration of residual stresses and strains induced from the forming processes prior to welding. Comparisons of FE predictions with experimental results are presented where it is appropriate. It is shown that the geometrical distortion and residual stresses and strains caused by welding can be minimised through process optimisation. It is therefore demonstrated that finite element analysis can be applied to better understand the SAW process and hence be a useful tool for future process development and control with the view of optimising product properties. (C) 2001 Elsevier Science B.V. All rights reserved.