Finite Element and Experimental Analysis of Residual Stresses in Electron Beam Welded Nickel-Based Superalloys

In this paper, two different nickel-based superalloys, namely Inconel 718 and Nimonic 80A were joined using electron beam welding techniques with three different welding parameters. A finite element analysis (FEA) using Abaqus software was carried out to calculate the residual stresses due to welding. Both transverse and longitudinal residual stresses were determined. Also, an X-ray residual stress measurement system, μ-X360 Ver. 2.5.6.2 was used for measuring transverse residual stress along and across the weld centerline. The transverse residual stress found by FEA and that measured experimentally was nearly the same thus validating the FEA. Also, the peak values of longitudinal residual stress found using the FEA were close to the yield strengths of the base metals as found elsewhere.