Finite Element Simulation and Experimental Validation of Welding Distortion of Fillet Welded T-joints

This research presents a numerical simulation for predicting welding induced distortion with an experimental validation. Three experimental specimens of S355J2G3 structural steel with thicknesses of 3mm, 5mm and 8mm have been used as test cases. In order to validate the results an experiment was set up to gain detailed information about distortions occurring in single fillet welded T-joints. The non-linear heat transfer analysis is used and heat source is modeled with the Goldak's double ellipsoidal distribution by using SYSWELD in the gas metal arc welding (GMAW) process. This study employs the finite element (FE) method to evaluate residual stresses and angular distortions. A series of FE simulations and corresponding experiments are performed to evaluate the depth of penetration in the cross sections, angular distortions that occur after welding, temperature distribution, and residual stresses. A coordinate measuring machine and a 3D non-contact scanning device are used to measure the angular distortions and displacement distributions, respectively. The results show that controlling welding process via simulations can significantly enhance the performance of process, and help to minimize distortions and decrease costly design errors.