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<p>Residual stresses arising mainly due to the rapid and uneven non-uniform heating and cooling can be more than the yield strength of parent metal and may cause plastic deformation in the welded structure. High tensile residual stresses, when combined with applied service loads, lower the load-bearing capacity of welded joints and make them more prone to fatigue and creep which may significantly influence the structural integrity and service life of welded components. Therefore, a newly designed and patented modified weld torch nozzle with an innovative cooling arrangement was used for successful fabrication of dissimilar narrow gap weld between P92 and SS304 steel using superalloy IN625 filler via multi-pass pulsed gas metal arc welding. The present study investigates welding residual stresses distribution using non-destructive synchrotron X-ray diffraction and finite element method-based numerical simulations. The findings from simulation further reveal that after first weld pass, peak von Mises stress is 254.2&#xa0;MPa and maximum principal absolute stress 211&#xa0;MPa in the welded structure. However, after the second weld pass, von Mises reduced by 16.05% to 213.4&#xa0;MPa indicate stress relaxation due to tempering effect, while maximum principal absolute stress rises slightly by 0.95% to 213&#xa0;MPa, indicating stress redistribution rather than fully relaxation. Moreover, the distribution of residual stresses is notably narrower and in reasonable agreement with experimental outcomes.</p>

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Synchrotron XRD for Residual Stress Measurement in Multipass Narrow Gap Dissimilar weld of P92 and SS304 Steel

  • 期刊论文

  • 发表日期：

    2025年12月18日

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  • Pavan Meena,
  • Ramkishor Anant

摘要

Residual stresses arising mainly due to the rapid and uneven non-uniform heating and cooling can be more than the yield strength of parent metal and may cause plastic deformation in the welded structure. High tensile residual stresses, when combined with applied service loads, lower the load-bearing capacity of welded joints and make them more prone to fatigue and creep which may significantly influence the structural integrity and service life of welded components. Therefore, a newly designed and patented modified weld torch nozzle with an innovative cooling arrangement was used for successful fabrication of dissimilar narrow gap weld between P92 and SS304 steel using superalloy IN625 filler via multi-pass pulsed gas metal arc welding. The present study investigates welding residual stresses distribution using non-destructive synchrotron X-ray diffraction and finite element method-based numerical simulations. The findings from simulation further reveal that after first weld pass, peak von Mises stress is 254.2 MPa and maximum principal absolute stress 211 MPa in the welded structure. However, after the second weld pass, von Mises reduced by 16.05% to 213.4 MPa indicate stress relaxation due to tempering effect, while maximum principal absolute stress rises slightly by 0.95% to 213 MPa, indicating stress redistribution rather than fully relaxation. Moreover, the distribution of residual stresses is notably narrower and in reasonable agreement with experimental outcomes.