Numerical and Experimental Analysis of Temperature Field, Deformation, and Residual Stress in Two-Stage Single-Pulse Sub-Powder Welding Joints

This study investigates the temperature fields, distortion, and distribution of residual stresses in single-pulse sub-powder welding of structural steel. Both experimental and three-dimensional finite element modeling approaches were employed. The heat flux from the welding process was applied as a combination of volumetric and surface heat sources in a Fortran-based program. The indirect coupled method in Abaqus software was utilized for the elastoplastic analysis of the welding process. The dimensions of the molten pool and the heat-affected zone were measured experimentally using metallography and compared with the finite element model. The temperature fields and distortion obtained from the finite element model were also validated against the experimental results. Finally, the influence of constraints on the degree of distortion and residual stresses in the analyzed structure was examined. The comparison of the numerical and experimental results shows good agreement, demonstrating the modeling approach's ability to accurately predict temperature distribution, deformation, and residual stresses in the sub-powder welding process.