Measurement and prediction of residual stresses in thick-section steel welds

Abstract

Significant levels of residual stress are developed in the production of thick-section steel welds. Residual stress can be measured by a variety of methods, although few offer the ability to determine the spatial distribution completely through the thickness. This paper summarizes recent developments in the deep-hole method for measuring residual stresses in thick-section welds. Experimental results obtained from a variety of welded steel components are described. The measurement method has also been used to provide validation for finite element simulations of residual stresses in a welded cylinder-to-nozzle stainless steel component. The paper describes the finite element weld analysis and compares the results with measurements obtained from several locations in the complex geometry. Overall, there is good agreement between the predicted and measured distributions of residual stress, but the magnitudes of predicted stress tend to be greater.