Jiang, WeiYahiaoui, Kadda2008-06-062008-06-062007Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 221(4): 225-2341464420710.1243/14644207JMDA151http://hdl.handle.net/2436/29647The Journal’s editorial board deemed it timely to dedicate an issue to address recent developments in the field and to highlight challenges to industry to exploit state-of-the-art modelling techniques. This paper was included in the special issue and describes the application of commercial finite element software to model the multipass fusion welding process.The current paper presents recently completed work in the development of advanced multi-pass weld modelling procedures, with the ultimate objective of predicting weld residual stress distributions in thick-walled complex geometries. The modelling technique was first developed using simple three-dimensional geometries, for which experimental data was available for validation purposes. All the non-linearities associated with welding, including geometry, material, and boundary non-linearities, as well as heat source movement were taken into account. The element removal/reactivate technique was employed to simulate the deposition of filler material. Combined with a newly developed meshing technique, the model was then applied to predict residual stress distributions for a relatively thick stainless steel piping branch junction. Finally, a parametric study was conducted to assess the effects of various manufacture-related welding parameters on the final residual stress fields. The interpass temperature and cooling rate were found to be the two most sensitive parameters affecting resultant residual stresses. The residual stress profiles can be optimized relatively easily by adjusting these parameters. This research demonstrated that the developed modelling technique has potential in multi-pass welding process optimization and wide industrial applications including weld repairs.(Professional Engineering Publishing)enMultipass weldingWelding processModellingResidual stressFinite element analysisPiping componentsEngineering technologyProduct designMetal componentsJournal articleProceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications