Simulation and validation of residual stress in electron beam welding and heat treatment of high-temperature alloys
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摘要:
为了揭示高温合金电子束焊接及热处理后残余应力分布规律，开展了电子束焊接和焊后热处理过程残余应力场模拟及试验研究。采用双椭球体与锥形体组合的热源模型来模拟焊接过程中电子束的热输入，模拟熔池形貌与实际焊接熔池形貌相吻合；模拟得到的接头残余应力沿焊缝中心向两侧呈“M”形双峰状对称分布，距焊缝中心线约3 mm处达到残余拉应力峰值268 MPa。基于ABAQUS UMAT子程序开发了考虑固态相变的热处理模拟方法，以模拟热处理后残余应力分布，结果表明：热处理后焊板残余拉应力峰值降低了48%，而峰值所在位置未发生改变。进而采用XRD法开展了实际焊板焊后及热处理后残余应力测量试验，与模拟结果对比表明：模拟得到的焊缝附近残余应力分布规律与试验结果较为一致，且焊接残余应力模拟峰值误差不超过3%而热处理后模拟峰值误差不超过11%，验证了模拟方法的有效性。
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关键词:
- 电子束焊接（EBW） /
- 焊后热处理（PWHT） /
- 残余应力 /
- X射线衍射（XRD） /
- 相变
Abstract:To reveal the distribution pattern of residual stress in high-temperature alloys after electron beam welding and heat treatment, simulation and experimental research of the residual stress field during the electron beam welding and subsequent heat treatment process were conducted. A dual ellipsoidal and conical heat source model was used to simulate the thermal input of the electron beam during welding, which matched well with the actual weld pool morphology. The simulated residual stress in the joint exhibited a symmetrical “M”-shaped double-peak distribution along the weld center, with a maximum residual tensile stress of 268 MPa occurring approximately 3 mm from the weld centerline. Based on an ABAQUS UMAT subroutine, a heat treatment simulation method considering solid-phase transformations was developed to simulate the residual stress distribution after heat treatment. The results indicated that the peak residual tensile stress in the welded plate decreased by 48% after heat treatment, while the location of the peak remained unchanged. Furthermore, XRD measurements were conducted on the actual welded plates after welding and heat treatment. A comparison with the simulation results showed that the distribution pattern of residual stress near the weld matched well with the experimental results, with a simulation peak error of no more than 3% for welding residual stress and no more than 11% for post-heat treatment residual stress, thereby validating the effectiveness of the simulation method.
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图 1 焊接及热处理过程多场耦合关系示意图
Figure 1. Schematic diagram of the multi-field coupling relationship during the welding and heat treatment process
图 4 焊接及焊后热处理数值模拟过程
Figure 4. Numerical simulation process of welding and heat treatment
图 7 热处理过程模拟子程序计算迭代流程
Figure 7. Iterative calculation flow of the subroutine for heat treatment process simulation
图 11 焊后焊板上表面残余应力分布云图
Figure 11. Residual stress distribution contour map on the surface of the welded plate after welding
图 12 焊接温度与残余应力关系
Figure 12. Relationship between welding temperature and residual stress
图 13 焊板路径Line 1～Line 3的残余应力分布曲线
Figure 13. Residual stress distribution curve for the welding path Line 1 to Line 3
图 14 焊板距焊缝中心不同距离沿厚度方向残余应力变化
Figure 14. Variation of residual stress along the thickness direction at different distances from the weld center
图 15 考虑相变影响的热处理焊板上表面残余应力云图
Figure 15. Residual stress contour map on the surface of the welded plate after heat treatment considering solid-state phase transformation
图 16 焊后热处理模拟同一路径上应力对比
Figure 16. Stress comparison along the same path in post-weld heat treatment simulation
图 19 焊板残余应力模拟结果与实际测量结果对比
Figure 19. Comparison of the simulation results of the residual stress of the welded plate with the actual measurement results
图 20 焊后热处理残余应力模拟结果与实际测量结果对比
Figure 20. Comparison of simulated residual stress results after heat treatment with actual measurement results
表 1 EBW工艺参数
Table 1. EBW process parameters
参数 数值 加速电压V/kV 80 电子束流I/mA 35 焊接速度v/（cm/min） 112 初始电流Fo/mA 423 聚焦电流Fb/mA 418 真空度/10−3 Pa 7 
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表 2 GH4169材料属性
Table 2. Properties of GH4169 material
参数 t/℃ 20 100 300 500 900 1200 比热容c/（J/（kg·℃）） 437 502 546 730 798 膨胀系数α/10−6 ℃−1 13.2 13.8 14.6 18.4 热导率κ/（W/（m·℃）） 13.4 14.65 17.59 20.10 25.96 泊松比μ 0.3 0.3 0.3 0.31 0.34 0.38 弹性模量E/GPa 205 201 189 176 1 屈服强度σs/MPa 685 670 520 263
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表 3 热源模型参数
Table 3. Parameters of the heat source model
参数 数值 ar/mm 2 af/mm 1 b/mm 1.4 re/mm 0.6 ri/mm 0.5 η 0.85
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