Stress-strain evolution in cast IN-738 superalloy single fusion welds

A three-dimensional finite element elasticplastic model was developed to study localized plastic strains and residual stresses that exist in a body that has previously been subjected to nonuniform temperature changes. The mechanical model was used to compute the evolution of plastic strains and residual stresses of welded material. The thermal gradient histories calculated during the GTA welding of cast IN-738LC alloys were imposed as load conditions on structural calculations. It can be clearly seen that at constant heat input, the level of plastic strains and the level of residual (Mises) stresses increase with welding speed. The model predicts highest residual stresses in regions of highest elastic strains, in agreement with conventional phenomenological material models where the macroscopic residual stress is always directly related to the macroscopic elastic strain. The highest residual stresses are located at the fusion line (where coarser dendrite secondary arm spacing exist); and the highest plastic strains are located at centerline (where finer dendrite secondary arm spacing exist). The calculations were performed using ABAQUS ^® FE code on the basis of a time-increment Lagrangian formulation.