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forecasting of welding distortions in large-sized structures

The prevention of welding distortions is one of the most important and, at the same time, most difficult issues in welding engineering. The above-named distortions result from the combined effect of the shrinkage of solidifying weld metal and the shrinkage occurring in the partially melted zone (primarily in the HAZ). Welding distortions often preclude the obtainment of proper joints in large-sized elements and, could even lead to the disqualification of the final product failing to satisfy related standard requirements concerning maximum distortion values. In spite of extensive research focused on welding distortions, they remain the primary issue accompanying the making of steel structures. Various industrial sector organisations express their need for solutions making it possible to forecast the presence of welding distortions. The possibility of forecasting the probable structure imperfections during assembly and the prevention of such imperfections as early as at the design stage and when scheduling assembly make it possible to reduce costs and delays resulting from the removal of distortions. The use of appropriate methods can reduce welding distortions yet it does not ensure their entire elimination. Engineering practice relies on analytical methods involving calculations of total distortions present in elements of welded structures having one and two-sided longitudinal welds, transverse distortions generated during the butt welding of sheets as well as local distortions generated as a result of the loss of stability of thin-walled welded structures. Knowledge concerning possible welding distortions can also be obtained by performing FEM-based numerical analyses concerned with the welding of structures.