Mechanism clarification and mitigation measures of radial deformation induced by girth welding of thin-walled pipes

Girth welding is extensively utilized in connecting pipeline structures. Excessive welding deformation may result in a decrease in ultimate bearing capacity and fatigue life. This research explores the characteristics and underlying mechanics of radial deformation in thin-walled girth welded pipes and proposes mitigation measures. Initially, several 304 stainless steel pipes were joined utilizing four distinct welding procedures. Welding deformation and residual stress distribution were measured using a 3D coordinate measuring machine (CMM) and the Cos α X-ray diffraction (XRD) method, respectively. Subsequently, numerical models were developed to simulate the welding process and verify the accuracy of the fusion zone, residual stress field, and radial deformation in the models. The mechanism of radial deformation was further elucidated based on the inherent strain method. The results show that the direction of radial deformation relies substantially on the hoop plastic strain. Hoop tensile plastic strain corresponds to radial outward deformation, while hoop shrinkage plastic strain corresponds to radial inward deformation. In addition, the influence of axial constraint on the formation process and results of hoop plastic strain, as well as the effect of heating zone width on radial deformation, was studied. Through simulation outcomes, the research suggests employing a regulated heat source method to mitigate radial deformation, which could potentially reduce deformation by 92.8%, offering considerable advantages in deformation mitigation and welding efficiency augmentation.