This paper presents a comparative study of three- and two-dimensional axisymmetric finite element (FE) analyses of a welded pipe–flange joint for residual stresses and deformations in order to identify their merits or demerits. Sequentially coupled thermal stress analysis is performed to simulate single pass metal inert gas welding. Butt weld geometry with a single ‘V’ for a 100 mm nominal diameter pipe and same sized weld neck type ANSI class #300 flange is used. The heat input is modelled by using the Goldak double ellipsoidal heat source model. Temperature dependent material properties are used and deposition of filler metal is obtained by element birth and death feature. Both thermal and structural FE models are validated with experimental measurements. Residual stresses predicted by two-dimensional model are generally on the higher side and hence more conservative. However, we conclude that the three-dimensional FE model is preferable for the prediction of flange face distortion since it is a vital parameter for flange joint performance.
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Abid et al. (2005) studied this question.