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Finite element modelling and experimental validation of microstructural changes and hardness variation during gas metal arc welding of AISI 441 ferritic stainless steel

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Abstract

Grain growth and hardness variation occurring in high-temperature heat affected zone (HAZ) during the welding processes are two thermal dependant aspects of great interest for both academic and industrial research activities. This paper presents an innovative finite element (FE) model capable to describe the grain growth and the hardness decrease that occur during the gas metal arc welding (GMAW) of commercial AISI 441 steel. The commercial FE software SFTC DEFORM-3D™ was used to simulate the GMAW process, and a user subroutine was developed including a physical based model and the Hall–Petch (H-P) equation to predict grain size variation and hardness change. The model was validated by comparison with the experimental results showing its reliability in predicting important welding characteristics temperature dependant. The study provides an accurate numerical model (i.e. user subroutine, heat source fitting, geometry) able to successfully predict the thermal phenomena (i.e. coarsening of the grains and hardening decrease) that occur in the HAZ during welding process of ferritic stainless steel.

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Availability of data and material

Not applicable

Code availability

commercial FE software SFTC DEFORM-3D™

Abbreviations

C 0 :

Numerical constant

C 1 :

Numerical constant

D :

Current grain size

D 0 :

Initial grain size

FE:

Finite element

FEM:

Finite element method

FZ:

Fusion zone

GMAW:

Gas metal arc welding

GTAW:

Gas tungsten arc welding

HAZ:

Heat affected zone

H-P:

Hall-Petch

HV:

Hardness Vickers

IRC:

Infra-red camera

Q :

Activation energy for grain growth

R :

Gas constant

T :

Current temperature

TIG:

Tungsten inert gas

a :

Heat source parameter

b :

Heat source parameter

c 1 :

Heat source parameter

c 2 :

Heat source parameter

d :

Average grain size

k :

Numerical constant

k y :

Numerical constant

k 0 :

Numerical constant

σ y :

Yield strength

σ 0 :

Numerical constant

m :

Numerical constant

t :

Time

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Authors and Affiliations

  1. Department of Mechanical, Energy and Management Engineering, University of Calabria, 87036, Rende, CS, Italy

    Serafino Caruso

  2. School of Metallurgy and Materials, University of Birmingham, Birmingham, B15 2TT, UK

    Stano Imbrogno

Authors
  1. Serafino Caruso
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Contributions

Conceptualization, S.C. and S.I.; methodology, S.C. and S.I. software, S.C.; validation, S.C.; formal analysis, S.I.; investigation, S.C. and S.I.; resources, S.C. and S.I.; data curation, S.C. and S.I.; writing–original draft preparation, S.C. and S.I.; writing–review and editing, S.C. and S.I.; visualization, S.I.; supervision, S.C. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Serafino Caruso.

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Caruso, S., Imbrogno, S. Finite element modelling and experimental validation of microstructural changes and hardness variation during gas metal arc welding of AISI 441 ferritic stainless steel. Int J Adv Manuf Technol 119, 2629–2637 (2022). https://doi.org/10.1007/s00170-021-08401-8

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