Thermal and mechanical evolution of welding-induced buckling distortion

The evolution of the buckling phenomenon starts during the weld cooling cycle, caused by an onset inelastic strain incompatibility condition. This initial bifurcation phenomenon may continue to grow until the completion of the cooling cycle, which results in the final buckling distortion of the plate. With lower heat input and/or smaller plate dimensions this initial instability may stop during the cooling cycle due to diminishing strain incompatibility and recovering of the plate rigidity. The buckling evolution process is complex due to the highly nonlinear nature of the welding problem. This paper studies this buckling evolution process using an integrated experimental and numerical approach. Bead-on-plate welds of AH36 steel were experimentally studied. The welding process was numerically simulated and analyzed using a three-dimensional, thermo-elastic-plastic, large deformation model. The transient stress bifurcation phenomenon and the displacement evolution process were analyzed to understand the critical weld conditions causing the final buckling distortion of the weldment. The critical weld conditions were evaluated on the longitudinal inherent shrinkage (plastic) strain distribution in the weldment.