IWE4-3 - Residual Stresses

IWE – theory:
4. Fabrication and procedures
Chap. 4.3 Residual Stresses and Distortion

Influencing factors ……………………………………………………………….
Thermal data of the materials ………………………………………………….
Origin of the residual stresses and deformation ……………………………..
Magnitude of longitudinal and transverse shrinkage stresses ….…………..
Relationship between heat input, shrinkage stresses and distortion ………
Methods of residual stress measurement …………………………………….
Welding sequence techniques………………………………………………..
Effects of residual stresses on the behavior of the structure in service…..
Methods of reducing residual stresses or distortion ………………………....
Correction and removal of welding deformation (pressing, rolling, local
heating, etc.) ……………………………………………………………………..
Examples of control of distortion
© Birger Sørenes/Audun Tveit

1
1. Welding stresses
We have earlier been dealing with welding stresses, see chapter 3.3.
Let us study a steel bar laying on a friction free basement heated up to 600o C. The bar is free
to expand and a temperature-strain will occur:
Expansion coefficient for steel, = 1.2 * 10-5 mm/(mm* oC)
Relative expansion, t = * T = 1.2 * 10-5 * 600 = 7.2 * 10-3
If the longitudinal expansion was blocked, the temperature increment in the start phase will
result in a elastic strain with corresponding stresses in the bar. As the temperature pass 400o
C, the strength in the material will be reduced drastically and at 600o C the bar got a plastic
strain/deformation. The bar will got a volume-increase in a direction where there is none
resistance, at this temperature the bar has none push force. During the cooling process
afterwards, the steel-bar will recover most of the strength and Emodul at about 300o C.
By cooling further on from this level the material will act elastic. If the bar is in a gripping
intension (for example welded in both ends), we will receive residual stresses in the bar:
Residual = E modulus * t = 210000 * 1.2 * 10-5 * 300 = 755 MPa
The bar will contract until the residual stress(tension) is equal to the YS value for the material.
Notice! that there is none stress-effect during heating, it is the condition during cooling which
determine the level of residual stresses.
Notice that the process is none-reversible when we have local heating around a weld. The
explanation is that the strength in the material disappear during heating
The material has a decreasing pressure strength during heating.

The material has an increasing tensile strength during cooling.
The shrinkage is a result of the variation in strength during heating and cooling.
An intensive local heating for instance a Longitudinal shrinkage in the weld

welding process, result in shrinkage if the direction:
metal parts have a possibility to free
movements.
2
Stress distribution over a weld zone::
Be aware of R – residual stress. This value is difficult determine exactly. In connection to

welding there will always arise stresses cause to local heating/cooling. Local heating/cooling
result in local expansion and contraction. Thin plates will deforms, more deformation  less
residual stresses. In thick material the residual stresses is almost at the level of Yield
stress: R = Re
Tensile stress
compression compression
Note that the tensile stresses are located a little bit outside the fusion line(FL) in HAZ. The
FL-area is a critical crack-start-area.
Distribution of weld stress in welded profiles:

(Reference: Per K. Larsen)
fy = Yield stress in base material; c– compression stresses
We conclude that during welding, stresses will occur in HAZ exceeding the Yield Stress. The
consequence is that the material is fasten  Dislocations moves over the neighbour-grain and
locks in new positions  The strength increase.
In HAZ there will be a development of strength caused by local yielding. Investigation done
by Akselsen & Rørvik at NTNU in 1989 resulted in the following diagrams:
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Normal heat input:
High heat-input :
The diagram above present extreme high local residual stresses in HAZ.
4
Example:
The strength values depends on Nominal Heat input:

5
2. Deformation.
Deformation depends on the condition, i.e. stiffness of the construction. If the construction
part is able to move, deformation will appear and the residual stress level will be at a
minimum. Residual stresses are inversely proportional with the grade of deformation.
Deformation depends on the ratio between the cross section area of the weld and the area of
the plate-parts oriented right-angled on the longitudinal direction of the weld. The shrinkage
force which will appear may result in considerable bending if the weld is located eccentric
with respect to the neutral axis of the cross section:
2.1 Bending of beams
Example(Beam): We got the following welding procedure

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7
We could reduce the distortion by reducing the web height, The weld closer to to the neutral
axis.
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Another possibility is to reduce the web-thickness  Reduce the weld deposit

9
The advantage
The advantage by pre-calculation of the grade of deformation, is that we in some cases may
be able pre-bend the element the opposite way and let the welding operation flatten the
element. Theoretically this will result in a weld without any residual stresses.
2.2 Angle deformation.
The 3 diagram below present angle deformation in C- Mn-steel as a function of :

1) a-size/thickness, 2+3) Number of strings
( Reference: Svejsecentralen, Publikasjon K 72001/15)
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2.3 Transverse shrinkage in steel:
Welding steel: The transverse shrinkage is more dominating compare to longitudinal

shrinkage.
The transverse shrinkage is a function of groove area. Example:
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2.4 Shrinkage of aluminium
Table for weld shrinkage of aluminium(boat-profiles)
Material- Transverse shrinkage Longitudinal shrinkage

thickness
Groove shrinkage Rib shrinkage Shrinkage
300 mm
t(mm) K1 ( mm ) K2(mm) K3(mm) pro meter

4 0.75 1 0.75
5 0.75 0.75 0.75
6 1 0.75 0.75
7 1 0.5 0.5
8 1,5 0.5 0,5
9 1,5 0.5 0.25
10 2 0.3 0.25
11 2 0.3 0.1
12 2 0.2 0.1
13 2.5 0.2
14 2.5 0.1
15 3 0.1
20 3
30 3
40 3
The table above is experience data(Finland) and is made for thin plates in aluminium, fast
ferries. K3 is a experience data connected to aligning when the length exceed 300 mm. Over
12 mm thickness it has none value.
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Example of calculation of shrinkage during welding of aluminium plates.

8000mm
12mm
12 mm
7 mm
Keyto symbol: = Rib ; = groove
Longitudinal shrinkage is always based on the “worst cas”, that means all the plates has the
same shrinkage index. In this case one choose the values for 7 mm plate thickness( This plate
has the highest index)
Longitudinal shrinkage : K2 + K3 = 4(number of frames) x 0,5 + 8 x 0,5 = 6 mm
Transverse shrinkage is calculated for each thickness-area: K1 + K2
7 mm plate area:
0.5 groove K1 = 1 x 0,5 = 0,5 mm
4 Ribs  K2 = 4 x 0,5 = 2,0 mm
12 mm plate area:
1.5 groove  K1 = 1,5 x 2 = 3,0 mm
5 Ribs  K2 = 5 x 0,2 = 1,0 mm
---------------
Sum Transverse shrinkage: = 6,5 mm
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3. Welding sequence
To reduce the level of residual stresses, The Welding Institute recommend the following
welding sequence welding a pipe:
15
Example of bad solution:
All passes have stop and start in the same area.
See Power Point presentation in folder for presentasjonsfiles(Norwegian version)
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IWE – theory:

4. Fabrication and procedures

Chap. 4.3 Residual Stresses and Distortion

© Birger Sørenes/Audun Tveit

Expansion coefficient for steel, = 1.2 * 10-5 mm/(mm* oC)

Relative expansion, t = * T = 1.2 * 10-5 * 600 = 7.2 * 10-3

Residual = E modulus * t = 210000 * 1.2 * 10-5 * 300 = 755 MPa

The material has a decreasing pressure strength during heating.

An intensive local heating for instance a Longitudinal shrinkage in the weld

Stress distribution over a weld zone::

Be aware of R – residual stress. This value is difficult determine exactly. In connection to

Distribution of weld stress in welded profiles:

fy = Yield stress in base material; c– compression stresses

Normal heat input:

The strength values depends on Nominal Heat input:

2.1 Bending of beams

Example(Beam): We got the following welding procedure

Another possibility is to reduce the web-thickness  Reduce the weld deposit

2.2 Angle deformation.

The 3 diagram below present angle deformation in C- Mn-steel as a function of :

2.3 Transverse shrinkage in steel:

Welding steel: The transverse shrinkage is more dominating compare to longitudinal

2.4 Shrinkage of aluminium

Table for weld shrinkage of aluminium(boat-profiles)

Material- Transverse shrinkage Longitudinal shrinkage

t(mm) K1 ( mm ) K2(mm) K3(mm) pro meter

Example of calculation of shrinkage during welding of aluminium plates.

Keyto symbol: = Rib ; = groove

Longitudinal shrinkage : K2 + K3 = 4(number of frames) x 0,5 + 8 x 0,5 = 6 mm

Transverse shrinkage is calculated for each thickness-area: K1 + K2

Example of bad solution:

All passes have stop and start in the same area.

See Power Point presentation in folder for presentasjonsfiles(Norwegian version)

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