Optimization of Welding Sequence and Improvement of Welding Process for Large-Diameter Curved Penetrations of Thick Plates

To reduce welding deformation during the automated welding of intersection seams on thick plate curved penetrations and thereby improve welding quality and efficiency, an optimized method for segmented and multi-layer multi-pass welding sequences, along with welding process improvement strategies, is proposed. First, based on the welding model of the curved penetrations, a multi-layer multi-pass welding trajectory equation is designed. Next, a Gaussian heat source model is selected, and numerical simulation theories for welding temperature and stress fields are established using finite-element theory. Then, for the intersection seams of curved components with three different thicknesses, four numerical tests of segmented welding sequence optimization are carried out using welding finite-element simulation theory. Finally, the optimal welding process for the welding sequence is improved using orthogonal experimental methods, and the optimal welding process parameters for curved components with different thicknesses are determined. The optimization of welding sequences for intersection seams on three types of thick plates shows that the optimal sequence for segmented welding is first to perform upper–lower diagonal symmetry, followed by left–right symmetry. Compared to other welding sequences, the proposed method reduces welding deformation by an average of 9.24% and welding stress by an average of 7.40%, which verifies the effectiveness of the welding sequence optimization presented in the paper.