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Vol.25, No.3, 2025, pp. 487–494 |
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ANALYSIS OF THERMAL AND RESIDUAL STRESSES IN MULTILAYER WELDED STAINLESS-STEEL PIPES USING DEFLUX AND FILM SUBROUTINES Abdelhakim Amine Djendara1
1) University of Science and Technology of Oran-Mohamed Boudiaf (USTO-MB), AlLGERIA A.A. Djendara https://orcid.org/0009-0001-5736-306X 2) National Polytechnic School of Oran-Maurice Audin, ALGERIA M. El Amine Khiari https://orcid.org/0009-0009-9379-2038 , *email: mohamedelamine.khiari@gmail.com ; A. Benzaama https://orcid.org/0000-0002-3564-6157
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Abstract The study provides a comprehensive analysis of the impact of welding parameters, specifically welding speed and the number of passes, on the residual stress distribution in AISI 304 (Z7CN18-09) austenitic stainless steel tubes. A three-dimensional finite element model (FEM) is developed in ABAQUS® to simulate the circumferential welding process. DFLUX and FILM subroutines are employed to represent double-ellipsoid moving heat source and thermal boundary conditions, respectively. Model validation is achieved by comparing simulated weld bead profiles and thermal cycles with experimental data, yielding excellent agreement (deviation < 5 %). The coupled thermal-mechanical analysis enables the evaluation of the spatiotemporal evolution of the temperature field at various welding speeds (80, 160, and 240 mm/min) and the distribution of axial and circumferential residual stresses across the tube thickness. The numerical results highlight the significant influence of welding parameters on the magnitude and distribution of residual stresses. Optimised welding speeds are shown to reduce maximum stress levels, while multi-pass welding improves stress homogenisation. Keywords: • AISI 304 stainless steel • residual stresses • finite element method (FEM) • multi-pass welding • heat transfer |
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