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<p>Residual stress and deformation occur during the welding process due to the inherent structural complexity and thin-walled configurations of gas turbine combustion liners, which seriously affect the dimensional accuracy and service performance of the components. In this study, the tungsten inert gas welding (TIG) experiment was carried out on a 2-mm-thick N263 nickel-based superalloy plate, and the corresponding finite element (FE) model was established. The optimal parameters for TIG welding were determined through plate welding experiments, with a welding current of 90 A and a travel speed of 2&#xa0;mm/s identified as the most effective settings. The reliability of the simulation results was verified from three aspects: temperature, stress, and deformation. For the initial combustion liner model, the structure is first simplified. Subsequently, the simplified model is divided into mappable geometric blocks to establish a finite element simulation model. The effects of welding sequence, welding direction, and fixture release method on post-welding stress and deformation are analyzed individually. The results indicate that implementing a welding sequence involving sequential welding from the weld seam near the upper edge of the combustion liner downward, combined with the alternate welding alternating and the application of a room-temperature release fixture, can effectively reduce residual welding stress from 1016.59 to 838.16&#xa0;MPa. Post-weld deformation decreases from 1.39 to 0.99&#xa0;mm. Furthermore, the distribution of both stress and deformation becomes more uniform, providing a theoretical basis and practical methods for the optimization of welding processes for complex thin-walled components in aerospace.</p>

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Analysis of Factors Influencing Stress and Deformation in Tungsten Inert Gas Welding of Complex Thin-Walled Combustion Liners via Finite Element Model

  • 期刊论文

  • 发表日期：

    2025年12月1日

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  • Yanqiong Sun,
  • Yuhang Zhu,
  • Hongxi Jin,
  • Yanhong Wei,
  • Xiangbo Liu,
  • Yuanyang Gao,
  • Jiacheng Chu

摘要

Residual stress and deformation occur during the welding process due to the inherent structural complexity and thin-walled configurations of gas turbine combustion liners, which seriously affect the dimensional accuracy and service performance of the components. In this study, the tungsten inert gas welding (TIG) experiment was carried out on a 2-mm-thick N263 nickel-based superalloy plate, and the corresponding finite element (FE) model was established. The optimal parameters for TIG welding were determined through plate welding experiments, with a welding current of 90 A and a travel speed of 2 mm/s identified as the most effective settings. The reliability of the simulation results was verified from three aspects: temperature, stress, and deformation. For the initial combustion liner model, the structure is first simplified. Subsequently, the simplified model is divided into mappable geometric blocks to establish a finite element simulation model. The effects of welding sequence, welding direction, and fixture release method on post-welding stress and deformation are analyzed individually. The results indicate that implementing a welding sequence involving sequential welding from the weld seam near the upper edge of the combustion liner downward, combined with the alternate welding alternating and the application of a room-temperature release fixture, can effectively reduce residual welding stress from 1016.59 to 838.16 MPa. Post-weld deformation decreases from 1.39 to 0.99 mm. Furthermore, the distribution of both stress and deformation becomes more uniform, providing a theoretical basis and practical methods for the optimization of welding processes for complex thin-walled components in aerospace.