"Finite Element Analysis of Residual Stress and Heat Distribution in Plasma-Transferred Arc Hard Facing of SS304"

Abstract

Plasma-transferred arc (PTA) welding is an advanced thermal process for applying wear and corrosion-resistant layers to metallic surfaces. This research explores the modeling and simulation of PTA hardfacing process using Finite Element Analysis (FEA). The study focuses on the development of an autogenous heat source model and its impact on residual stress, observed through atomic displacement due to heat distribution. Various generations of weld heat source models are reviewed, culminating in the use of a double ellipsoidal power density distribution for accurate representation. The thermal transient simulation employs temperature-dependent properties of SS304, with results informing structural analysis to determine residual stress and displacement. Experimental validation through bending displacement and dye-penetration tests confirms the model's accuracy, highlighting the critical influence of heat input parameters on residual stress and crack formation. This research Plasma-transferred arc (PTA) welding is an advanced thermal process for applying wear and corrosion-resistant layers to metallic surfaces. This research explores the modeling and simulation of PTA hardfacing process using Finite Element Analysis (FEA). The study focuses on the development of an autogenous heat source model and its impact on residual stress, observed through atomic displacement due to heat distribution. Various generations of weld heat source models are reviewed, culminating in the use of a double ellipsoidal power density distribution for accurate representation. The thermal transient simulation employs temperature-dependent properties of SS304, with results informing structural analysis to determine residual stress and displacement. Experimental validation through bending displacement and dye-penetration tests confirms the model's accuracy, highlighting the critical influence of heat input parameters on residual stress and crack formation. This research underscores FEA's pivotal role in optimizing PTA welding processes for enhanced product quality and reliability.underscores FEA's pivotal role in optimizing PTA welding processes for enhanced product quality and reliability.