MME321 Presentation Group 12

MME321 Presentation
Heat Flow, Residual Stress and

Distortion in Welding
Group Members;
160406043 JOKI-LASISI ABDULSALAM TEMI
160406023 AKANO ZAINAB
160406024 ABOLARIN PELUMI SULTAN
160406054 OlALEYE TAIWO OLUDARE
170406510 AKINTUNDE OLUWATOFUNMI SAMUEL
160406035 OLUGBAIKE ENIOLA ESTHER
160406049 GASPER OLAWALE
160406053 ADENIRAN ADEKUNLE RILWAN
160406015 YAYAH TEMIDAYO
160406028 HOSINOU BENEDICT

Heat Flow
 During fusion welding, the interaction between the base metal and the heat
source leads to the rapid heating and melting and the vigorous circulation of
molten metal.
 In the weld pool, the circulation of this molten metal is driven by buoyancy; the
surface tension gradient, jet impingement, or friction; and, when electric current
is used, electromagnetic forces.
 The resulting heat transfer and fluid flow affect the transient temperature
distribution in the base material, the shape and size of the weld pool, and
solidification behavior.
 The variation of temperature with time, often referred to as the thermal cycle,
affects microstructures, residual stresses, and the extent of the distortions in the
weldment. On the surface of the weld pool, the temperature distribution affects
the loss of alloying elements by evaporation as well as the absorption and
desorption of hydrogen and other gases. Thus, the composition of the weldment is
affected. In the interior of the weld pool, inclusions grow or dissolve, depending on
the local temperature. The control of these temperature fields and cooling rates is
essential to ensure sound welds with the desired fusion-zone geometry, chemical
composition, and microstructure, as well as with low residual stress and distortion
Heat Flow continued
 An understanding of heat transfer is important in the production of welds in
as much as the properties of a weldment are controlled by its geometry and
by the composition and structure of the materials being welded. The
measurement of the temperature fields that form on the surface of the weld
pool and in the weldment provides important information about heat transfer
characteristic.
 Temperature measurements in the solid regions commonly involve the
placement of thermocouples, which are cumbersome and expensive, in holes
drilled in the plates. Therefore, a recourse is to use quantitative calculations
to gain insight into the phenomenon of heat transfer during fusion welding.
 In the weld pool, heat is transported by means of convection and conduction
Diagrams of Heat Flow in Welding
Residual Stresses in Welding
 Welding residual stresses are caused by differential thermal expansion and
contraction of the weld metal and parent material. Residual stress levels in and
near to the weld can be very high, up to material yield strength magnitude in
highly constrained situations, which is the case in most real structures.
 Residual stress is caused by the contraction of the weld metal as it cools from the
solidus to room temperature. This contraction produces tensile stresses that are
opposed by the compressive stresses set up by the surrounding metal. The
opposing stresses result in a weld that is in a state of residual stress.
 There are two types of residual stress in welding: static and dynamic. Static stress
is the result of the contraction of the weld metal as it cools from the solidus to
room temperature. Dynamic stress is the result of the movement of the welding
torch or electrode during welding.
 There are several ways to minimize residual stress in welding, including using low-
stress welding techniques, post-weld heat treatment, special welding fixtures or
jigs, and selecting the proper filler metal.
 Residual stress can have a significant effect on the performance of a weldment. It
can cause warping and distortion, cracking, and other problems.
Residual Stresses Continued
 The residual stress formula is:

 Residual Stress = (Weld Metal Contraction) – (Surrounding Metal
Expansion) where,
 Weld Metal Contraction = the contraction of the weld metal as it cools
from the solidus to room temperature.
Residual Stress Diagrams
Distortion in Welding
 Welding distortion can be defined as “the non-uniform expansion and

contraction of weld metal and adjacent base metal during the heating
and cooling cycle of the welding process”. Distortion is a consideration
when arc welding all materials, and the principals behind this reaction
are fundamentally the same.
 Distortion can result when the parent metal being welded on
warps due to excessive heat created by the welding process.
This usually occurs on thinner gauge sheet metals as they lack the
surface area to dissipate the heat.
Types of Welding Distortion
 LONGITUDINAL DISTORTION: Longitudinal shrinkage happens along the length of
the weld. On cooling, the weld and the surrounding area contracts and shortens the
workpiece as a result. This type of distortion is greatest when the workpiece is not
properly secured.
 TRANSVERSE DISTORTION: This distortion happens when the metal contracts after
welding and pulls its edges towards each other. It happens because the metal had
initially expanded but experienced a higher rate of contraction when cooling.
 ANGULAR DISTORTION: Angular distortion happens when the angles between the
welded parts are altered by contraction. The contraction is greater on the top as there
is a larger weld pool at the top than the bottom.
 BUCKLING, BOWING AND WARPING :If all of the above distortion types happen on a
single joint, the results are several complex distortions. The distortions may be in the
form of bowing, buckling and warping. In bowing, the weld centre does not coincide
with the neutral axis of the cross-section.
 Warping is formed when parts of the weld dish inside between several stiffened points.
There can be several dish sections along the length of the weld.
 Elastic buckling causes the metal sheet to be curved along the width. If there is an
attempt to flatten such a joint, it would most likely snap.
Longitudinal Distortion Transverse Distortion
Buckling, Bowing and Warping Angular Distortion

Prevention of Distortion
 Weld placement.
 Reducing the volume of weld metal.
 Reducing the number of runs.
 Use of balanced welding.
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MME321 Presentation

Heat Flow, Residual Stress and

160406028 HOSINOU BENEDICT

 The residual stress formula is:

 Welding distortion can be defined as “the non-uniform expansion and

Buckling, Bowing and Warping Angular Distortion

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