Title:
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Characterising high energy beam welding in structural steels with numerical simulation and validation
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Welding has been one of the most extensively used joining processes for engineering applications
and is the most frequently used process in nuclear power plants. Welding involves complex thermal,
mechanical and metallurgical phenomena, affecting the microstructure of the material and generating
internal or residual stresses and distortions in the process. Residual stresses are locked up stresses
resulting from the thermal and/or mechanical processing of the parts. Residual stresses are inevitable
and usually detrimental to the service life of a component often resulting in collapse or total structure
failure.
Numerous welding techniques have been developed over the past decades with the aim to reduce
the residual stresses and enhance the performance of the component. These techniques need to
be thoroughly studied and understood before implementing them in actual service. Electron beam
welding and laser beam welding are two emerging techniques that are most promising because of
many favourable features, including narrow fusion width to depth ratio, high welding speeds and
capability to join metals that are dissimilar without any filler material. However to understand the
full capability of these methods, it is essential to study the processes and their consequences on the
joint.
This dissertation presents the development of numerical and experimental approach to analyse
electron beam welding and laser beam welding in a modified 9Cr-lMo (P91) butt welded plate.
Modified 9Cr-lMo steel is used in nuclear power plants because of its high desirable properties such
as strength and creep resistance at high temperatures. A number of simulation procedures using
sequentially coupled thermo-mechanical analysis of the welding process are developed to study the
welding process and the generation of residual stresses. The model incorporates the sol id-state phase
transformation, exhibited by P9l steel during rapid cooling stage, which is the critical factor in the
final residual stress field.
The finite element models are validated using neutron diffraction measurements. The validated
models are then used to study the influence of material properties, hardening models, annealing
temperature and the boundary conditions on the final residual stress distribution . Also post-weld
heat treatment used for relaxing the residual stresses due to welding is simulated and the extent of
relaxation is studied. Uniaxial cross-weld creep tests are conducted on electron-beam welded samples
to investigate the creep life. With the experience gained from modelling electron beam welding on
P91 plates, an attempt has been made to develop a finite element model to simulate the electron
beam welding of dissimilar metal welds in a butt plate made of P91 and AISI 316LN SS steels. The
developed model is evaluated based on neutron diffraction experiments.
Significant amount of effort has been directed towards developing an accurate and reliable numerical
model to simulate the complex phenomena and severe non-linearity associated with welding
processes such as temperature dependent material properties, hardening models, boundary conditions
and solid-state phase transformation, which is the main purpose of this research. The residual
stresses are predicted successfully. It is shown that the major contributor towards the residual stress
profile is the volume change associated with the solid-state phase transformation during the cooling
stage. Other factors such as temperature dependent thermo-mechanical properties, material
hardening properties and boundary conditions have relatively less influence on the residual stresses.
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