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Finite Element Analysis of Residual Stress Level Prediction for TIG Welding Process

Tungsten Inert Gas (TIG) welding process requires high heat input during the process, when the material is cooled down non-uniform distribution of thermal strain causes residual stress which can weaken the material and fatigue life of the material. The residual stress can be measured from method such as x-ray diffraction (XRD), using strain gage of drilled hole and so on. A numerical method of constructing a finite element analysis (FEA) model can be used for predicting the residual stress level of the welding process. This paper uses the TIG welding condition for stainless steel grade 304 that the material provided the highest level of tensile strength, obtained from previous study, as a condition for the FEA model. The residual stress results from the FEA predictive model and the results from XRD were compared. In the FEA model, the workpiece, heat affected zone (HAZ), and filler metal assumed to be the same. The results showed consistent residual profile between the model and the actual measurement from XRD, but there was some discrepancy of the magnitude of residual stress which can due to the type of filler material that was used.