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<p>To enhance the safe operation and long-term reliability of offshore wind turbines, a three-dimensional thermo-structural coupled model of the tower flange ring weld was established using Abaqus finite element analysis software. This study systematically investigates the influence of different heat inputs and preheating temperatures on the temperature distribution, stress distribution, and deformation during the welding process of large-capacity offshore wind turbine tower flange rings. Nine sets of combinations of different heat inputs and preheating temperatures were designed to perform numerical simulation analyses of temperature distribution, residual stress, and welding deformation during the welding process. Simulation results indicate that the post-welding residual stress was minimal under the conditions of the fourth set of parameters, while the post-welding deformation was minimal under the conditions of the first set of parameters. High heat input combined with low preheating exacerbates temperature gradients and uneven thermal strain, thereby leading to significant welding deformation; conversely, low heat input combined with low preheating exhibited the lowest transverse and longitudinal stresses across all paths, which helps reduce thermal gradients and effectively suppress the occurrence of deformation. Through signal-to-noise ratio analysis and grey correlation evaluation, the fourth set of parameters exhibited the highest signal-to-noise ratio, with a grey correlation coefficient of 0.996, indicating the best overall performance. Accordingly, process parameters of 1260&#xa0;J heat input and 140&#xa0;°C preheating temperature were selected for welding test validation. The measured temperature curves and residual stress distributions were highly consistent with the simulation results. The maximum average deformation was 0.196&#xa0;mm, and the mechanical properties of the welded joint were satisfactory, meeting engineering application requirements. The optimized welding process can effectively reduce residual stress and deformation while improving the overall performance of the joint.</p>

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Minimizing Residual Stresses and Deformation in the Circumferential Welds of Large-Capacity Offshore Wind Turbine Tower Flanges: Control of Heat Input Parameters

  • 期刊论文

  • 发表日期：

    2026年7月24日

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  • Yuhua Wu,
  • Ran Ren,
  • Xuanze Yang,
  • Lei Wang,
  • Xianfeng Gao

摘要

To enhance the safe operation and long-term reliability of offshore wind turbines, a three-dimensional thermo-structural coupled model of the tower flange ring weld was established using Abaqus finite element analysis software. This study systematically investigates the influence of different heat inputs and preheating temperatures on the temperature distribution, stress distribution, and deformation during the welding process of large-capacity offshore wind turbine tower flange rings. Nine sets of combinations of different heat inputs and preheating temperatures were designed to perform numerical simulation analyses of temperature distribution, residual stress, and welding deformation during the welding process. Simulation results indicate that the post-welding residual stress was minimal under the conditions of the fourth set of parameters, while the post-welding deformation was minimal under the conditions of the first set of parameters. High heat input combined with low preheating exacerbates temperature gradients and uneven thermal strain, thereby leading to significant welding deformation; conversely, low heat input combined with low preheating exhibited the lowest transverse and longitudinal stresses across all paths, which helps reduce thermal gradients and effectively suppress the occurrence of deformation. Through signal-to-noise ratio analysis and grey correlation evaluation, the fourth set of parameters exhibited the highest signal-to-noise ratio, with a grey correlation coefficient of 0.996, indicating the best overall performance. Accordingly, process parameters of 1260 J heat input and 140 °C preheating temperature were selected for welding test validation. The measured temperature curves and residual stress distributions were highly consistent with the simulation results. The maximum average deformation was 0.196 mm, and the mechanical properties of the welded joint were satisfactory, meeting engineering application requirements. The optimized welding process can effectively reduce residual stress and deformation while improving the overall performance of the joint.