Numerical and experimental validation of gas metal arc welding on AISI 441 ferritic stainless steel through mechanical and microstructural analysis

Abstract Residual stresses and strains, distortions, heat-affected zone (HAZ), grain size changes hardness variation during gas metal arc welding (GMAW), are fundamental aspects to study control processes. For this reason, numerical simulations of the processes represent more frequently used tool better analyse several characterizing joining process with aim reduce lead time production costs. In present study, an uncoupled 3D thermo-mechanical analysis was carried out by two commercial finite element method (FEM) software model experimental single bead GMAW AISI 441 at different set-up. The HAZ measured temperatures were calibrate heat source both codes, then a validation phase done test robustness developed analytical procedures. One predict residual strains distortions welded components, while in second software, user routine implemented, including physical based Hall-Petch (H-P) equation, change evolution, respectively. results demonstrate that predicted mechanical microstructural agree those experimentally found showing reliability codes predicting thermal phenomena analysed process.