The Thermomechanical Finite Element Analysis of 3003-H14 Plates Joined by the GMAW Process

The gas metal arc welding (GMAW) process was used to weld 3003-H14 plates under restricted and unrestricted thermal expansion. Experimental and numerical analysis were conducted to determine the relation between weld thermal cycles and residual stresses. A customized data acquisition system with K-type thermocouples was used to measure the weld thermal cycles, while residual stresses were determined by the hole drilling method. Thermo-mechanical simulation models for the two restricted conditions were implemented from the experimental data obtained. A double ellipse heat distribution geometry was used to model the heat moving source by using the finite element method. Thermal rates and peak temperatures were approximated by the finite element model with 2% difference, with respect to the experimental weld thermal cycles. Longitudinal and transverse normal residual stresses determined by the finite element model showed a good comparison with experimental measurements. The larger residual stresses were in the transverse direction for both clamping conditions, which indicated that working loading paths along the lateral direction of the welded plate are more influenced by the post-welding residual stresses.