Experimental and numerical study of welding-induced deformation and residual stress in 6082 aluminum: Model validation and process design guidance

Abstract

This study presents an integrated numerical and experimental investigation into the effects of welding parameters on deformation and residual stress in butt-welded joints made of 6082 aluminum alloy. A sequentially coupled thermo-mechanical finite element model was developed using a dual heat source approach and compared with experimental data, including temperature histories, fusion line profiles, deflection, and residual stress. Sensitivity analysis confirmed the reliability of the applied thermal boundary conditions. Experimental validation demonstrated the model’s accuracy in predicting residual stress and deflection, supporting its applicability in welding process optimization. A parametric study, based on a Taguchi design of experiments and analysis of variance (ANOVA), quantified the influence of welding sequence, clamping, and interpass time. The results revealed that while tighter clamping reduced deformation, it also led to increased residual stresses, highlighting a trade-off in process optimization. Among the examined parameters, clamping was identified as the dominant factor influencing both deflection and residual stress, as confirmed by ANOVA results. In contrast, welding sequence and interpass time exhibited no statistically significant effect on either outcome. This integrated approach supports the design of improved welding procedures by identifying key parameter effects and enabling better control of dimensional accuracy and residual stress.

Keywords

• Welding process design
• Deflection
• Stresses
• Thermo-mechanical behavior
• Simulation