Modeling of Residual Stresses in a Butt-welded Joint with Experimental Validation
2D-modeling of arc welding in butt-joint configuration was performed in this study considering thermal-structural interactions. Thermal behavior was modeled in COMSOL Multiphysics® using the Heat Transfer Module with weld heat input as a Gaussian pulse whereas structural behavior using Structural Mechanics Module. Thermal-elastic-plastic behavior model based on Von Mises yield criteria and isotropic strain hardening was used to compute evolving plastic strains. Residual stress was predicted by weld simulation across the thickness-oriented plane as iso-stress contours. Studied COMSOL Multiphysics model was experimentally validated by conducting in-situ residual stress measurements from XRD method on a physically butt-welded coupon with identical welding parameters. A close agreement (within 15 %) was found between COMSOL Multiphysics simulated and XRD measured values of residual stress, establishing the accuracy of the studied model.