Thermally induced residual stresses due to welding can significantly impair the performance and reliability of welded structures. Existing research has ignored the effect of fluid flow in the weld pool on the temperature field of the welded joint. Hence, for a more accurate estimation of the thermally induced residual stresses it is desired to incorporate the weld pool dynamics into the analysis. Various welding parameters (like, welding speed, current, arc length, surfactant activity, plasma drag etc.) influence the weld pool dynamics, which in turn affect the thermal history of the workpiece. Such integration would help in better quantification of thermal stress evolution and residual stress distribution in the welded joint. In this study, a three-dimensional numerical model for the thermo-mechanical analysis of Gas Tungsten Arc (GTA) welding of a butt joint of thin stainless steel plates has been developed. The effects of welding parameters on the residual stress distribution are documented.

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