Simulation and validation of experimental residual stresses of dissimilar AA2124 and AA7075 TIG weld joint using ANSYS APDL

Aluminum alloys such as AA2124 and AA7075 are widely used in aeroplane construction. Certain applications of aircraft manufacturing need dissimilar joint of the aforementioned aluminum alloys. The investigation involves predicting residual stresses in multiple directions (X, Y, and Z) along the transverse direction of welding in butt-welds using ANSYS APDL. Simulated stresses which are tensile along weld bead are well concurrent with the XRD experimental findings (Gas Turbine Research Establishment). During TIG welding of these plates different currents were used to form dissimilar joints and all of them form visible cracks along the weld bead. This formation of cracks is well accord with both simulated and experimental tensile residual stresses. The simulated stresses are compared to the numerical values i.e., experimental findings, and the discrepancy of less than 10% has been noticed. Thus, simulated model can be used as tool for prediction of cracks for joining dissimilar aluminum alloys of above said.