Numerical simulation and control of welding distortion for double floor structure of high speed train

The welding heat source models and the plastic tension zone sizes of a typical weld joint involved in the double floor structure of high speed train under different welding parameters were calculated by a thermal-elastic-plastic FEM analysis based on SYSWELD code.Then,the welding distortion of floor structure was predicted using a linear elastic FEM and shrinkage method based on Weld Planner software.The effects of welding sequence,clamping configuration and reverse deformation on welding distortion of floor structure were examined numerically.The results indicate that the established elastic FEM model for floor structure is reliable for predicting the distribution of welding distortion in view of the good agreement between the calculated results and the measured distortion for real double floor structure.Compared with the welding sequence,the clamping configuration and the reverse deformation have a significant influence on the welding distortion of floor structure.In the case of30 mm reverse deformation,the maximum deformation can be reduced about 70%in comparison to an actual welding process.

Effect of Nb and Mo on the Microstructure, Mechanical Properties and Ductility-Dip Cracking of Ni–Cr–Fe Weld Metals

A series of Ni-Cr-Fe welding wires with different Nb and Mo contents were designed to investigate the effect of Nb and Mo on the rnicrostructure, mechanical properties and the ductility-dip cracking susceptibility of the weld metals by optical microscopy （OM）, scanning electron microscopy, X-ray diffraction as well as the tensile and impact tests. Results showed that large Laves phases formed and distributed along the interdendritic regions with high Nb or Mo addition. The Cr-carbide （M23C6） was suppressed to precipitate at the grain boundaries with high Nb addition. Tensile testing indicates that the ultimate strength of weld metals increases with Nb or Mo addition. However, the voids formed easily around the large Laves phases in the interdendritic area during tensile testing for the weld metal with high Mo content. It is found that the tensile fractographs of high Mo weld metals show a typical feature of interdendritic fracture. The high Nb or Mo addition, which leads to the formation of large Laves phases, exposes a great weakening effect on the impact toughness of weld metals. In addition, the ductility-dip cracking was not found by OM in the selected cross sections of weld metals with different Nb additions. High Nb addition can eliminate the ductility-dip cracking from the Ni-Cr-Fe weld metals effectively.

Numerical Investigation on Residual Stresses of the Safe-End/Nozzle Dissimilar Metal Welded Joint in CAP1400 Nuclear Power Plants

The residual stress evolution in a safe-end/nozzle dissimilar metal welded joint of CAP1400 nuclear power plants was investigated in the manufacturing process by finite element simulation. A finite element model, including cladding,buttering, post-weld heat treatment (PWHT) and dissimilar metal multi-pass welding, is developed based on SYSWELD software to investigate the evolution of residual stress in the aforementioned manufacturing process. The results reveal a large tensile axial residual stress, which exists at the weld zone on the inner surface, leads to a high sensitivity to stress corrosion cracking (SCC). PWHT process before dissimilar metal multi-pass welding process has a great in?uence on the magnitude and distribution of final axial residual stress. The risk of SCC on the inner surface of the pipe will increase if PWHT process is not taken into account. Therefore, such crucial thermal manufacturing process such as cladding, buttering and post-weld heat treatment, besides the multi-pass welding process, should be considered in the numerical model in order to accurately predict the distribution and the magnitude of the residual stress.

Effect of Post-weld Tempering on the Microstructure and Mechanical Properties in the Simulated HAZs of a High-Strength-High-Toughness Combination Marine Engineering Steel

The effects of tempering temperatures on the microstructure and mechanical properties of the simulated coarse-grain heataffected zone(CGHAZ) and inter-critical heat-affected zone(ICHAZ) were investigated for a high-strength-high-toughness combination marine engineering steel.The results demonstrate that the microstructure of the simulated CGHAZ and ICHAZ after tempering is characterized by tempering sorbites and coarse grain in the simulated CGHAZ.As tempering temperature increases,the tensile strength of the simulated CGHAZ and ICHAZ decreases and the Charpy absorbed energy of the simulated ICHAZ at-50℃increases remarkably,but the impact toughness of the simulated CGHAZ is not improved.After tempering at 550℃,the coarse flake carbides,which distribute at the prior austenite grain and martensite lath boundaries,deteriorate the impact toughness of the simulated CGHAZ.With the increase in tempering temperature,the morphology and the size of the carbides gradually change from coarse flake to fine granular,which is beneficial to the improvement of impact toughness.However,the coarse-grain size of the simulated CGHAZ and the M23 C6-type carbide precipitated along the grain boundaries weakens the enhancing effect of carbides on impact toughness.

Enhanced Fatigue Property of Welded S355J2W Steel by Forming a Gradient Nanostructured Surface Layer

Welded joints are usually characterized by microstructural and compositional inhomogeneities, which may significantly degrade their fatigue properties and result in unpredictable failures. The present work demonstrates a novel and simple method to effectively optimize the microstructure in the surface layer and promote the fatigue properties of welded specimens. By a recently developed approach—surface mechanical rolling treatment(SMRT), a gradient nanostructured surface layer is formed on welded S355 J2 W steel specimens. The mean grain size is refined to nanometer scale, and the hardness is significantly enhanced in the SMRT surface layer. Independent of the initially inhomogeneous microstructure and hardness distributions, the microstructure and hardness distributions in the surface layers are comparable on different zones of a welded specimen after SMRT with the same procedure. Consequently, fatigue property of the SMRT specimens is significantly enhanced relative to that of the as-welded specimens within the high cycle fatigue regime.