| Citation: | LI Jinhong, LIU Xiaogang, YANG Mohan. Simulation and validation of residual stress in electron beam welding and heat treatment of high-temperature alloys[J]. Journal of Aerospace Power, 2025, 40（11）：20240725 doi: 10.13224/j.cnki.jasp.20240725
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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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