Numerical Modeling of Residual Stresses in Welded Aluminum Manifold Joints in Oil and Gas Piping Systems: Effects of Cooling Rate and Microstructural Evolution Using ABAQUS

Welding is a critical fabrication technique in oil and gas piping systems, particularly when joining aluminum manifold joints due to their excellent strength-to-weight ratio and corrosion resistance. However, the process inherently introduces residual stresses and microstructural transformations that can affect long-term joint performance. This study presents a numerical investigation using ABAQUS to analyze the influence of welding speed on temperature distribution, cooling rate, microstructural evolution, and residual stresses in aluminum manifold joints. A 3D finite element model simulates the Gas Tungsten Arc Welding (GTAW) process, incorporating a moving heat source, temperature-dependent material properties, and solid-state transformation behavior. Results reveal that increased welding speed significantly reduces peak temperatures and residual stress magnitudes, alters cooling rates, and influences grain refinement. These findings offer valuable insights for optimizing welding parameters to ensure the structural integrity of aluminum components in high-stakes energy applications.