Thermal, Metallurgical, and Mechanical Analysis of Single-Pass INC 738 Welded Parts
Abstract
1. Introduction
1.1. Moving Distributed Heat Sources
Prescribed Heat Flux Input on Surface
1.2. Prescribed Volumetric Heat Flux Input
1.3. Numerical Simulation
1.4. Assumptions
- The precise approximation of heat input energy widely affects the accuracy of the thermal distribution model for the values for the two heat input models are obtained through trial and error to yield sufficiently; in our case they were adjusted to get the same heat flux and the maximum temperature as in literature [13,14,15,16].
- The butt weld of two plates is modeled in a single pass [17].
- The segregation effect and nonequilibrium solidification were neglected.
- All the material properties are described until the liquid phase of metal. When the material is liquid, the related rigidity and resistance are negligible, but both yielding strength and Young’s modulus were limited to small values (5 MPa and 0.1 GPa, respectively) to reduce computation time; the thermal expansion coefficient was considered very small in order to avoid computation divergence [3].
- The thermal conductivity is considered as transverse isotropic which increases heat exchanges in the welding direction (λ = 60 Wm−1 K−1 in the welding direction and λ = 30 Wm−1 K−1 in the other directions) [3].
- The vaporization of the metal is not taken into consideration but only the fusion process is considered.
- The fluid flow in the molten weld pool has not been considered [18].
- Elastic–plastic strain and thermal strain are inseparable.
- Thermal properties and stresses/strains related to temperature change linearly in small time increments [19].
2. Materials and Methods
2.1. Thermal Simulation of Plate Butt Joint Welding
Geometry Model and Meshing
2.2. Analysis Organisation
2.2.1. Step and Interaction
2.2.2. Load and Boundary Conditions
2.2.3. Job Execution
2.3. Welding Parameters and Material Model
2.4. Material Thermophysical Properties
2.5. Metallurgical Analysis
Mechanical Analysis
3. Results and Discussions
3.1. Heat Flux
3.2. Temperature Distributions
3.3. Metallurgical Analysis (Solidification Parameters)
Prediction of Cooling Rates and Dendrite Arm Spacings
- It can be clearly seen that in all welds the cooling rate is the highest at the center line.
- The dendrite arm spacings are approximatively similar; the maximum dendrite arm spacing errors are 3.5 µm for λ1 and 0.5 µm for λ2 between the two heat sources, as shown in Figure 15.
3.4. Mechanical Analysis
3.4.1. Residual Stresses Calculation
3.4.2. Displacement Fields Computation
4. Conclusions
- Two types of heat sources, surface distribution and volumetric input, were employed in the simulation.
- Thermal fields and heat fluxes were determined for both heat source models.
- Solidification parameters, such as dendrite arm spacings, were calculated based on predicted cooling rates at various points around the weld pools; these values were similar for both heat input methods.
- Transverse residual stresses were evaluated, and a hot cracking criterion was established to identify regions susceptible to hot cracking.
- The maximum transverse stress recorded was 1.1 GPa in the heat-affected zone (HAZ) for the Goldak heat input model.
- Distortions and strains of the welded plate were estimated for both heat sources.
- At the conclusion of the welding process, the Gaussian heat source resulted in a significant expansion of the fusion zone (FZ), as observed in the mapped residual stresses and displacement values, compared to the Goldak heat input.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Heat Source | Parameter | Notation | Value |
---|---|---|---|
Gaussian distribution | Radius of circular surface heat source (m) | r0 | 0.010 |
Goldak’s heat input | Length of front ellipsoidal (m) | af | 0.003 |
Length of rear ellipsoidal (m) | ar | 0.012 | |
Depth of the heat source (m) | c | 0.006 | |
Half width of the heat source (m) | b | 0.004 | |
Front heat fraction | ff | 0.6 | |
Rear heat fraction | fr | 1.4 |
Current (A) | Voltage (V) | Arc Efficiency | The Net Heat Input per Time Unit Q (W) | Speed (m/s) | The Net Heat Input per Length Unit Q (J/m) | Argon Flux (L/min.) |
---|---|---|---|---|---|---|
40 | 10 | 0.8 | 320 | 0.004 | 80 × 103 | 8 |
Parameter | Density (Kg/m3) | Latent Heat (J/Kg K) | TSolidus (°C) | TLiquidus (°C) |
---|---|---|---|---|
Value | 8110 | 300 | 1255 | 1355 |
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Saib, C.; Amroune, S.; Chebbah, M.-S.; Belaadi, A.; Zergane, S.; Mohamad, B. Thermal, Metallurgical, and Mechanical Analysis of Single-Pass INC 738 Welded Parts. Metals 2025, 15, 679. https://doi.org/10.3390/met15060679
Saib C, Amroune S, Chebbah M-S, Belaadi A, Zergane S, Mohamad B. Thermal, Metallurgical, and Mechanical Analysis of Single-Pass INC 738 Welded Parts. Metals. 2025; 15(6):679. https://doi.org/10.3390/met15060679
Chicago/Turabian StyleSaib, Cherif, Salah Amroune, Mohamed-Saïd Chebbah, Ahmed Belaadi, Said Zergane, and Barhm Mohamad. 2025. "Thermal, Metallurgical, and Mechanical Analysis of Single-Pass INC 738 Welded Parts" Metals 15, no. 6: 679. https://doi.org/10.3390/met15060679
APA StyleSaib, C., Amroune, S., Chebbah, M.-S., Belaadi, A., Zergane, S., & Mohamad, B. (2025). Thermal, Metallurgical, and Mechanical Analysis of Single-Pass INC 738 Welded Parts. Metals, 15(6), 679. https://doi.org/10.3390/met15060679