Validations of Computational Weld Models: Comparison of Residual Stresses

The objective of this project was to validate the capability of VrWeld to simulate the weld buildup process in two experimental setups. Setup I had a central depression with dimensions of 100 x 100 x 3 mm, while Setup II had a central depression with dimensions of 200 x 200 x 3 mm. This report documents the validation of the computer models capability to compute residual stress in overlay weld repairs of this type, i.e., does the model predict the measured residual stress with sufficient accuracy, reliability and robustness. For this project, the values of the computed residual stress data were mapped to the data points at which the residual stress was measured. Then two types of plots were made. The first is an image of the stress field determined by linear interpolation onto the preferred grid. The second is a plot of curves of the computed residual stress data and the residual stress along lines in the plane of the panel. For both types, one image of measured and one image of computed data is shown on each page to facilitate comparison. Whether the model predicts the measured residual stress with sufficient accuracy, reliability and robustness for a particular analysis would depend on the analysis.