Numerical analysis of residual stresses in dissimilar welded joint

Joining two dissimilar materials is one of the most innovative challenges in the field of welding. It is therefore important to study the manufacturability of such joints with the aim of minimizing the invasiveness, in terms of residual stress and deformation, of the welding process on the base materials. Welding parameters, preheating temperatures, and the number of passes can have a considerable effect on the integrity and final strength of the joint. The use of the Finite Element Method (FEM) to simulate thermo-mechanical behaviour during welding allows the evaluation of heat input and thermal gradients, thus providing information on the development of residual stresses and deformations during the welding and cooling phases. This study investigates the distributions of residual stresses induced by the welding process in dissimilar cast iron-steel butt joint using a finite element model to simulate its thermo-mechanical behaviour. The findings of this work provide a preliminary reference for future studies involving the use of this type of dissimilar joint.