Prediction of Welding Deformation and Residual Stresses in Fillet Welds Using Indirect Couple Field FE Method

Fillet welds are extensively used in shipbuilding, automobile and other industries. Heat concentrated at a small area during welding induces distortions and residual stresses, affecting the structural strength. In this study, indirect coupled-field method is used to predict welding residual stresses and deformation in a fillet joint due to welding on both sides. 3-D nonlinear thermal finite element analysis is performed in ANSYS software followed by a structural analysis. Symmetrical boundary conditions are applied on half of the model for simplification. Results of FE structure analysis predict residual stresses in the specimen. A comparison of simulation results with experimental values proves the authenticity of the technique. The present study can be extended for complex structures and welding techniques.