Finite element simulation of residual stresses and their measurement by contour method

A three-dimensional transient thermo-mechanical simulation has been performed on a welded Tee-joint using the finite element method, to predict longitudinal residual stresses. The uncoupled thermo-mechanical simulation consists of two stages. The first stage involves the prediction of the complete thermal history of the weldment. The second stage involves the thermo-mechanical simulation on the basis of the results of the first stage. Temperature dependent thermal and mechanical properties were incorporated in the simulation. A relatively new contour method was used to experimentally validate the longitudinal residual stresses obtained by the thermo-mechanical simulation. The experimental results agree well with the simulated results of residual stresses.