Computational modeling of residual stress in welded high-strength steel box sections

This study investigates the residual stress patterns of welded box-section members constructed from high-strength steel (HSS). A finite element method (FEM) model developed in ANSYS is validated using experimental data from previous studies. Additionally, experimental data are directly utilized in the analysis to reinforce and contextualize numerical outcomes. A comprehensive parametric analysis explores the impact of plate thickness, width-to-thickness ratio, steel strength, welding sequence, and welding conditions on residual stress distributions. The results reveal that tensile residual stresses near weld regions consistently reach 82.6–97.8% of the yield strength and primarily depend on steel strength, with minimal sensitivity to section dimensions. In contrast, compressive residual stresses in mid-panel regions decrease by up to 72.2% with an increase in width-to-thickness ratio from 3.0 to 23.0, and the reduction rate is influenced by plate thickness. Additionally, welding sequences significantly affect residual stress magnitudes without altering their general distribution patterns. Diagonal welding method in the same direction effectively reduces mid-panel compressive stresses by up to 17.0%, and butt welds generate approximately 48.3% lower residual stresses than fillet welds. A residual stress distribution model for HSS welded box sections is developed. The model shows good agreement with experimental data with average deviation within 9.5% and can serve as a simplified yet reliable input for structural design, safety assessment, and advanced finite element modeling of welded steel members.