Experimental validation of computational methods for welding distortion prediction

Abstract

Recent research by the authors on computational simulation of welding in the fabrication of thin stiffened steel plate is reviewed. The aim is to simplify the computational strategy in order to provide practical solutions to the prediction of welding distortion in multiply-stiffened structures. Uncoupled methods have been developed whereby the complex thermo-elastic-plastic computational stage is replaced by simple analytical algorithms which directly connect the thermal analysis with the elastic structural analysis to provide the deformations due to welding distortion. The research has depended critically on full-scale welding tests to validate the simplifications and to provide insight concerning appropriate simplified models of the processes. Thermocouples and infrared imagery were used for thermal analysis and a special welding and scanning rig was developed to measure pre- and post-weld out-of-plane distortions and to monitor live deformations during welding.