Finite Element Simulation of Multi-Pass Welding of AA6061-T6 Plate-Sleeve: Effect of Different Yield Strengths of Weld and Base Metals

Plate-sleeve welded joints were general-purpose joints used in aluminum alloy spatial structures. In this study, FEM analysis of multi-pass welding of AA6061-T6 plate-sleeve was performed to investigate the effect of different yield strengths of weld and base metals on the predicted deformation and residual stress using ABAQUS. Finite element simulations with and without considering the yield strength of the weld metal (ER5356) were carried out, respectively. A corresponding welded joint was fabricated using MIG welding, and simulation predictions were compared with experimental measurements. The results indicate that the vertical deformation increases slightly, the residual stress of the weld zone decreases, and computing time reduces by 39.3%, considering the yield strength of ER5356. Besides, the stress distribution of the case with different yield strength is more complex, and the residual stress has a mutation at the interface between weld metal and base metal. From the perspective of simulation accuracy and efficiency, it is recommended to consider the yield strength of weld metal in the welding simulation of aluminum alloy.