Thermal and Stress Analysis in Butt, T-shaped and Tubular Joints in the Welding Process of Dissimilar Parts

Connecting parts through welding as permanent connections can play an important role in various industries. Despite the favorable load-bearing capabilities of joints resulting from welding dissimilar parts, they have some limitations that need to be identified and checked to optimize their use. One of the limitations is the behavior of parts under thermal stresses caused by the welding process. Thus, it is important to consider the welding conditions of the dissimilar parts in the contact area of the electrode and the welding seam, as this can significantly affect the mechanical performance of the welds. The research conducted in this study involved using the electric welding method with non-consumable tungsten electrodes under shielding gas (TIG) to connect aluminum and carbon steel parts. Ansys software was utilized to investigate the effect of thermal stress in the welding process for different joints. To ensure accuracy, parts were welded together practically under similar conditions, and the results obtained were compared with the results of the modeled method. First, the behavior of a steel sheet under the butt and Tee Joint and then the role of various factors on welding performance were investigated by modeling the process for a pipe in different conditions. Finally, due to the significant role of T-shaped joints in various industries, heat distribution, behavior, and stress analysis were investigated.