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Welding Deformation and Residual
Stress Prevention
Welding Deformation
and Residual Stress
Prevention
Second Edition
Ninshu Ma
Joining and Welding Research Institute, Osaka University, Osaka, Japan
Dean Deng
College of Materials Science and Engineering, Chongqing University,
Chongqing, China
Naoki Osawa
Department of Naval Architecture and Ocean Engineering, Osaka
University, Osaka, Japan
Sherif Rashed
Joining and Welding Research Institute, Osaka University, Osaka, Japan
Hidekazu Murakawa
Joining and Welding Research Institute Osaka University, Osaka, Japan
Yukio Ueda
Joining and Welding Research Institute, Osaka University, Osaka, Japan
Butterworth-Heinemann is an imprint of Elsevier
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
Copyright © 2022 Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording, or any information storage and retrieval system, without
permission in writing from the publisher. Details on how to seek permission, further information about the
Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance
Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copyright by the Publisher
(other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and experience broaden
our understanding, changes in research methods, professional practices, or medical treatment may become
necessary.
Practitioners and researchers must always rely on their own experience and knowledge in evaluating and
using any information, methods, compounds, or experiments described herein. In using such information
or methods they should be mindful of their own safety and the safety of others, including parties for whom
they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any
liability for any injury and/or damage to persons or property as a matter of products liability, negligence or
otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the
material herein.
ISBN: 978-0-323-88665-9
Since arc welding was invented in the late 19th century, welding has been widely used
as an essential technology for metal joining in construction. Generally, welding pro-
duces deformation and residual stress in welded products, which influences the quality
and performance of these products. Welding heat input is from the welding arc or laser
beam or electron beam. This heat induces melting of the metal and conducts in the
joint. Local expansion and contraction in the joint result in welding deformation
and residual stress. Many engineers and researchers have expended great efforts to
find ways to control these incidents. However, welding deformation and residual
stress still remain as difficult engineering problems. This is because the phenomena
associated with welding are complex and interdisciplinary.
After the digital computer was invented, new computational theories and methods
were developed, one of which is the finite element method. This method is a powerful
numerical analysis tool to solve complex problems. The author’s research group has
developed many computational methods of analysis for welding mechanics based on
the finite element method.
In 1971, Ueda and Yamakawa [1] succeeded in analysis of thermal elastic-plastic
behavior of butt joints of two plates during welding and published a paper on this
pioneering work. Since then, the group has continued to analyze various types of
welded joints, including multipass joints of very thick plates. With these efforts,
the group established a simulation method of thermal elastic-plastic behavior of
welded joints.
In parallel with these analyses, they examined the accuracy of the analysis, com-
paring with residual stresses measured on experimental models. During this process,
they paid special attention to the source of residual stress, called inherent strain, and
developed a very efficient method to predict welding residual stress and deformation.
Additionally, they presented a new rational measuring method of three-dimensional
residual stress in thick welded joints, utilizing a special feature of the inherent strain
method, which they discovered. The methods of analysis, prediction, and measure-
ment of weld deformation and residual stress have been further advanced, and a frame-
work of computational welding mechanics has been established [2].
Safety requirements for welded structures are becoming increasingly strict. To
meet these requirements, engineers engaged in structural design and quality control
often need to anticipate welding deformation and residual stresses with higher accu-
racy. This changing engineering environment requires them to have more opportuni-
ties to conduct welding analysis utilizing commercial software, either general or
specialized for welding. In order to use such software and evaluate the output effec-
tively, inexperienced engineers need a basic understanding of welding mechanics and
good practice in handling the software.
xiv Preface
The first edition [3] of this book was written to meet this demand, and it provided
the following elements:
1. The generation mechanism of welding deformation, residual stress, and inherent strain was
illustrated using a simple three-bar model, and through the illustration, basic theories were
formulated and analysis procedures were presented.
2. A FEM program, User Q&A, and 21 sets of sample data were provided to practice the basic
analysis of heat conduction, deformation, and residual stress due to welding under basic
plane stress and plane deformation conditions.
3. Examples of strategic methods and procedures to solve various welding-related problems
encountered in the process of construction were presented.
4. Appendices provided databases for welding residual stresses in various types of joints,
temperature-dependent material properties, and the basic three-dimensional equations,
among other data.
Ten years have passed since the first edition was published in 2012. New technology
has been developed and more welding-related problems are yielding to computational
analysis and synthesis. It was thought to be appropriate to update the first edition and
add new material addressing welding mechanics-related problems.
In the second edition, the first three chapters are the same as those in the first edi-
tion. In Chapters 1, 2, and 3, the mechanism of production of residual stress, defor-
mation, and inherent strain during welding is illustrated using the simple three-bar
model undergoing typical welding thermal cycles. The relational expressions between
them are derived. Through the illustration, with the aid of the inherent strain method,
the fundamental theory of measurement of residual stress is formulated, and the pro-
cedures of prediction of residual stress and deformation are presented. Considering the
fact that three-dimensional finite element analysis is commonly used nowadays,
Chapters 4, 5, and 6 of the first edition were deleted in the second edition.
In the new Chapter 4 of the second edition, various advanced computing methods
of welding thermal-mechanics are introduced, including heat source models, and the
finite element method for heat transfer and thermal stress analysis. In Chapter 5, ther-
mal elastic-plastic-creep behavior is introduced using a simple bar model, and welding
residual stress distributions in typical joints are discussed based on simulation results
and measured data. In Chapter 6, practical analysis methods including modeling
methods for welding assembly deformation are introduced. Chapter 7 presents predic-
tion examples of welding deformation for large-scale structural models and covers the
influence of constraint conditions and fabrication sequences on structural deforma-
tion. Chapter 8 discusses numerically computed and experimentally measured resid-
ual stress and deformation in additive manufacturing, such as 3D metal printing and
surface improvement techniques. Chapter 9 reuses Sections 7.1–7.6 from Chapter 7 of
the first edition, presenting strategic analysis of welding residual stress for
manufacturing problems such as welding-induced cracking, and implements the influ-
ence of residual stress on fatigue safety as well as buckling behavior of welded struc-
tures in the new Sections 9.6–9.10. In Appendix, a database of welding residual
distributions in various welded joints is summarized.
Preface xv
This second edition of the book has been written for the practicing engineer who
wishes to utilize computational analysis and prediction of welding residual stress and
deformation in their practical work, as well as for researchers who are engaged with
welding mechanics-related problems. The authors believe that the efforts of the
readers should contribute to developing their own computational analysis-based
manufacturing.
Ninshu Ma
Dean Deng
Naoki Osawa
Sherif Rashed
Hidekazu Murakawa
Yukio Ueda
References
[1] Y. Ueda, T. Yamakawa, Analysis of thermal elastic-plastic stress and strain during welding
by finite element method, Trans. Jpn. Weld. Soc. 2 (2) (1971) 90–100.
[2] Y. Ueda, A pioneer of computational welding mechanics and ultimate strength analysis
(ISUM), hall of fame, Ships Offshore Struct. (2020), https://doi.org/10.1080/
17445302.2020.1855500.
[3] Y. Ueda, H. Murakawa, N. Ma, Welding Deformation and Residual Stress Prevention, first
ed., Butterworth-Heinemann, Elsevier, 2012. ISBN 978-0-12-394804-5.
List of symbols
Continued
Ep Elastic-plastic modulus
e Base of natural logarithm
e∗ (6.4) Inherent strain
erav (4.109) Averaged square root index
ermax (4.109) Maximum error index
F Force, load
F (4.17) Radiation efficiency
F∗ Sum of external force and thermal load
Fconcentrate (4.112b) Concentrated nodal force
Ff, Fr (4.7) Heat distributing factors in the Goldak heat source
model
Fgravity (4.112b) Gravity-induced nodal force
FN, FT, FL, Fθ (6.14) Bonding forces
Fp (6.28) The share of the tendon force of each side of the plate
Fpressure (4.112b) The nodal force due to external pressure
Fw (6.28) The web share of tendon force
{F} (4.26) Heat flow matrix
{Fdamp} (4.112d) Damping nodal force vector
{Fext} (4.112b) External equivalent nodal force vector
{Fint} (4.112c) Internal equivalent nodal force vector
f (4.120) Yield function
f (6.4) Nodal force vectors
fB (4.59) Fraction of bainite
fM (4.57) Fraction of martensite
fS (4.11) Fraction of total heat transferred onto the surface
fV (4.12) Fraction of volumetric heat source
f(R) Fatigue enhancement factor
G (4.50) Shear modulus
H (6.23) Web height
HT (4.86) Thermal softening coefficient
H0 Coefficient of work hardening
H0 (4.86) Plasticity hardening tangent
[H∗] Elastic response matrix
[H∗]T Transposed matrix of [H∗]
h Thickness
I Welding current
K (4.57) Coefficient of
transformation
plasticity
[K] (4.23) Stiffness matrix
K Stress intensity factor (SIF)
Kc (6.14c) Large contact stiffness
Kmat Material’s fracture toughness in SIF unit
Kr SIF ratio
List of symbols xxi
Continued
Continued
Continued
Continued
The authors express their special appreciation to Professor Emeritus Yukio Ueda and
Hidekazu Murakawa, Professor Ninshu Ma for their encouragement in writing the sec-
ond edition by implementing new Chapters 4–9 and enhanced Appendix combining
Chapters 1–3 of the first edition. The authors wish to acknowledge their colleagues
and students who engaged in the associated research, the results of which are used
in this book. Sincere thanks are extended to Elsevier’s Science and Technology
Editorial and Book Production teams for their strong support in publishing this book.
Finally, and most importantly, the authors would like to acknowledge the support of
their family members, without whom this book would never have been completed.
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Language: English
I had known Harry Thurbley for ten years, and he was a phlegmatic
sort. He had the kind of unshakable calm and nerve you only find in
a man that's made peace with death a couple of times or so out
beyond the planets. Once I had seen him walk into a mining power
plant on Callisto and disarm a runaway pile that was due to explode
in three minutes and blast away half the moon.
When he came out he hadn't even been sweating.
But he was upset now. I tried to calm him, but I guess he had a
hunch. I had spent several years on Venus and knew the place as
well as any Terran. I tried to persuade him that Sukey Jones
wouldn't be in any danger so long as they stuck to the civilized
northern part, but he didn't seem to half hear what I was saying.
A month passed, and we made another trip beyond the Belt. When
we got back there was still no Sukey, and not even a letter. Harry
and I went into the Super's office and talked him into a transfer to
the Venus run for one trip.
It was less than five days later that we set the Altair down on the
surface of the White Planet at Medea, the biggest port city on Venus.
The low, spidery towers of the native architects of old were crowded
and overshadowed by Earthstyle skyscrapers which had grown up,
mostly, since the last time I had seen Venus, fifteen years ago.
It was Harry's first trip to the sister planet of Earth, and he seemed
surprised at the mushrooming civilization. But he still couldn't rest
until we'd given the ship into the hands of the ground crew and
gone to hunt Sukey and her mistress.
Mrs. Campbell, we discovered, had checked in at the Majestic Hotel
for one week, and left, giving no forwarding address. After that she
had been heard from in two or three of the border cities. She had
made the rounds of all the beauty parlors and quack establishments
in town. This was her fourth trip to Venus, and all of the merchants
knew her by sight.
But she was not, currently, visiting any of these places. It seemed
that Althea Campbell, a couple of days ago, had disappeared, which
was nothing to me, except that she had taken a tiny girl named
Sukey Jones with her.
Mrs. Campbell may have had acquaintances about Venus, but not
many friends. Especially among the natives, whom she loathed and
treated like scum. The natives of the temperate belts were
humanoid, and though primitive in culture, fairly intelligent.
They were thin, and not too bad-looking if you could get used to the
fish-belly whiteness of their scaly skins, and a partial lack of
symmetry in their bodies, such as having one eye a couple of sizes
bigger than the other one.
It was from one of the Venusians that we found our first clue. He
was Argol Beg, the head of the native Security Police, an individual
with silvery, heavy-lidded eyes, and long, nervous, quadruple-jointed
fingers.
He mentioned a name that I had heard a long time ago, and
forgotten. Marjud. Marjud had been one of the rebel chieftains who
had fought against the Alliance in the late Venerian sectional war,
and now was outlawed from the Northern settlements.
I call him a man, but I had seen pictures of Marjud once, and there
were features about that gross body of his that no one except a
Venusian would believe. He was a native of the steaming jungles of
the torrid zone, a forbidden area where the native form mysteriously
shifted and changed from generation to generation for reasons at
which the anthropologists could only guess. His race was still
barbaric, for the most part, which was why it was off limits.
It seemed that Marjud was now in the beauty racket. That could
have handed me a laugh, except that we were too worried about
Sukey.
We got a newspaper, the Medean Times, and sure enough, there
was his ad, in scrambled English that hadn't even been changed by
the proofreader.
The address of the contact man was given. I asked Argol Beg why
he had not arrested Marjud. But Marjud's man had set up in the
Colonial Quarter, where Argol Beg had no authority, and he was not
wanted by the Earth colonial police.
"Come on," I said to Harry. "Let's see if we can locate the old
gargoyle." Harry was pretty worried by this time, and he didn't half
understand what was going on, not knowing Venus.
"I'm with you, whatever you say," he said.
We visited the address given in the ad, and got to talk to a normal-
appearing native with slit eyes and a fishy stare. He said that Marjud
saw only Terran females, and he couldn't help us.
I persuaded him to change his mind in a few minutes, and then he
told us that Marjud was staying in a dhol cave outside the city. The
dhol caves were made by a long-dead, semi-intelligent race of
quadrupeds, and it wasn't uncommon for the none-too-particular
Venusians to set up housekeeping in them.
There was a guard hanging around the entrance to this one. The
contact man pointed out the guard and fled. The guard argued and I
had to slug him with the butt of my gun. Harry went over and looked
at him.
He turned to me and his face was clammy white. It was one of the
equatorial species.
"What's the matter?" I said.
"What is it?"
I told him. "Marjud is worse," I said.
"Stay here, Chuck," he said, drawing his own weapon. "If I don't
come out within five minutes, come in blasting."
She stood there looking scared, and not believing that it was really
me. Her eyes were big as dollars.
And when she was sure, the way she threw herself at me and
hugged me, it was embarrassing.
"Chuck, Chuck! I never thought I'd see you again. I never—I'm so
—!" And that was all I got out of her for the next couple of minutes.
I gave her my handkerchief to dab at her eyes, and I got the story
at last.
She had been there two days without food and water, locked in.
They had arrived a week ago, and during that time she had seen
nothing except the interior of this room.
Althea Campbell had heard rumors of the rainbow gardens, and that
the natives, by bathing in the radiation given off by the colored
mists, were able to restore youth and vigor for long periods of time.
She had seen the chance of restoring her own body to its youthful
bloom and of working the miracle that she had sought for so many
years on half a dozen planets. She had sought out Marjud, who
alone had contacts that could get them into the forbidden area.
"I still don't get it," I said. "Where is she now, and why has she got
you locked in here?"
"I was afraid after we arrived, and I didn't want to do it. She said we
had to take off our clothes and go with the priests into the rainbow
garden. I refused, and she slapped me and said that I was
impertinent and ungrateful. I threatened to run away and tell the
authorities, so they locked me in here.
"The she-devil!" I said.
"Oh, she's really not so bad," said Sukey, forgivingly. "It's just that
she's a little mad when it comes to being young and beautiful. She
was forever talking about the way her arms and legs looked, and all,
and crying, and bawling me out."
"Come on," I said. "Let's find Harry and get out of here."
Her lip quivered. "H-Harry? Is he here too?"
"Somewhere," I said, trying to frown at her, and not succeeding,
"and worried to death. If I was him I would skin you alive."
"I just wanted a chance to come to Venus. That's why I took the job
as maid to Mrs. Campbell. I knew that she was tremendously
wealthy and came to Venus every year to the beauty culturists."
I didn't press the subject. The sky over Venus hadn't faded her
complexion much, luckily.
It was still fine, even if she did look a little beat.
We went out into the hallway and I yelled for Harry. He answered.
He seemed to be outside.
I looked out one of the ventilation slits. He was standing out there
with his back to me, looking into the rainbow garden. The mists
were rising in wispy colors here and there, and I could tell without
looking at my chrono that the long Venusian night was approaching,
for the distorted shapes of the trees were vague, and could no
longer be seen more than a few yards away.
"Up here!" I said. And he looked up.
He pointed to the garden. "Thought I heard somebody calling out
there," he said, pointing.
"Don't go away," I said. "And don't go in there, whatever you do. I'll
be right out."
I grabbed Sukey's arm. "We'll surprise him," I told her.
Sukey Jones came up from behind Harry and put her hand on his
arm. He turned and they just looked at each other for the space of
half a minute.
Harry's voice was kind of choked. He said, "Sukey, I—"
And then we all heard it. It was a woman crying. The sound came
from the garden. Harry took a step toward the mists.
"Wait," I said. And I shouted, "Mrs. Campbell, is that you?"
"Here!" Her voice was faint and plaintive. Just as I had remembered
it.
"Come on out. We've come to take you home."
"I—I can't."
"How long has she been in there?" I asked Sukey. "Do you know?"
"All of the time, I suppose."
I shook my head. "It's risky business, but we can't leave her, I
suppose. I'll go in."
"I can't let you do that," Harry said. "I'm the logical one to go.
Listen!" We could hear her crying. A vexed, lost-little-girl sound.
I shoved Harry aside. "You don't know what you're getting into," I
said. "Take Sukey, and—"
That was the first and only time that Harry ever swung at me. The
first thing I knew, I was sitting on the ground with my head
spinning.
Harry was looking down at me and grinning sardonically. "I hated to
do that, Chuck," he said, "but you see, it has to be me that goes
after her."
He turned and took both of Sukey's thin shoulders in his hands. He
couldn't speak for a while. His eyes were talking, though; saying
they were awfully sorry. And then he took a couple of steps into that
colored mist before he stopped and looked back.
He was still smiling, but it was a secret smile. He said, "It's too bad,
Sukey, but you know, eighteen million bucks are eighteen million
bucks."
"What the—?" I said.
"Harry, darling, is that you?" The voice of Mrs. Campbell was closer
now.
"Coming, Althea dear!" he said, and laughed at me. "Do you
suppose I wasted all those Thursdays, Chuck?" he said. "'Bye. Take
care of Sukey for me. Althea and I'll be along later."
He turned his back on us and went deeper into the mists, calling her
name, spreading the bushes with his hands and trying to see her.
He was hazy now, hardly visible.
But I saw Althea Campbell just an instant before he did. She came
out of the rainbow mist from behind him, and her now-blonde hair
glimmered with reds and greens, and blues and gold and purple. Her
naked body was snow white. She had got her money's worth, I
suppose. Marjud had promised her that pale complexion.
And the curious radiations had given her smooth legs and arms that
were pearl-white and long, and supple, and graceful.
She came from behind Harry and put her arms around him.
All of them.
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