Mechanical Analysis of T-Joint Welding Plate using ANSYS

This study examines the mechanical behaviour and structural integrity of T-joint welds under thermal cycling, representing one of the most important issues from the structural point of view in applications like construction, automotive, and heavy machinery. In fact, because of their geometrical configuration and induced thermal stresses during both the welding and cooling process, T-joints are faced with problems of highly concentrated stresses, deformations, and elastic strains. In this regard, fatigue damage can develop after a certain period of time, as a result of which failure can occur. The objective of this work is to investigate the distribution of stresses and strains in T-joint welds to determine the regions of the weld that are prone to failure, besides proposing optimised welding strategies with the aim of attaining improved durability in the joint. In this paper, ANSYS FEA software is employed in an effort to simulate the effects of thermal cycling on the T-joint weld by studying equivalent stress, total deformation, and elastic strain along the weld bead and HAZ. It follows from the results that peak stresses are concentrated within the HAZ, while the maximum deformation happens around unsupported edges. Optimised cooling rate, structured support configurations, and tailored welding sequences were proposed to mitigate these effects.