Assessment of residual stresses in welded T-joints using contour method

Welded T-joints are commonly used in manufacturing of stiffened panels or crossbeams. However, welding of web-to-flange joint induces residual stresses and distortions resulting in significant challenges during both manufacturing and service. These issues can ultimately impact the structural performance, including fatigue and stability, and lifetime of the weldment. The purpose of current paper is determining the distribution and magnitude of manufacturing-induced longitudinal residual stresses in welded T-joints. Influence of hot rolling, thermal cutting, prestressing, welding, etc. are all included using the so-called contour method. Deformed surfaces are measured using coordinate measuring machine after wire electrical discharge machining of specimens. An inverse linear elastic finite element analysis is carried out for assessing residual stresses after data smoothing. Two-dimensional longitudinal residual stress patterns are evaluated in representative cross-sections clearly indicating high stress peaks near the welds, even exceeding yield strength of the base material. In addition, longitudinal membrane residual stresses are determined based on through-thickness stresses. In addition, a simplified residual stress model, satisfying the requirement for equilibrium of internal forces and bending moments, is developed for welded T-joints with double-sided fillet welds based on contour method results. [Display omitted] •A novel application of contour method is used for determining residual stresses.•Longitudinal residual stresses are assessed in welded T-joints.•Tensile residual stress peaks near the welds exceed yield strength of the material.•A simplified residual stress model is developed for welded structural steel T-joints.•Residual stress model satisfies equilibrium of internal forces and bending moments.