Process Modelling of the Electron Beam Welding of Aeroengine Components

A numerical process model is described for the prediction of residual stresses and distortion arising from the electron beam welding of Waspaloy. Simulations have been conducted with this model for welds performed at a number of focal positions of the electron beam. Comparison is made between the model predictions and experimental measurements of the thermal cycles, the residual stresses and distortion. Good agreement is observed between the model and experiment for the thermal cycles and residual stresses. Distortion csn also be predicted but some discrepancies have been noted.