Investigation of distortions in welded joints

The welding process combined with each component results in varying degrees of distortion due to thermal stresses. The distortions occurring on the welded parts can lead to functional impairment or even damage. Therefore, the impact of distortion on welded components is of great importance. In this thesis study, experimental and numerical analysis studies were conducted to investigate welding distortions. Welding methods in complex welded assemblies were simulated using finite element applications in the ANSYS program to numerically analyze welding distortions. The results of the numerical analysis performed within the scope of the thesis were compared with the results of experimental studies, demonstrating the accuracy of the numerical analysis solution parameters. Without changing the solution parameters validated in this way, the distortion effects caused by different welding methods in welded parts were examined. Necessary movement constraints were applied to prevent identified welding distortions. The numerical analysis of various welding methods facilitated the identification of optimal welding methods and the design of corresponding welding fixtures. It was found that the maximum axial distortion obtained from the continuous welding process performed without a fixture was reduced by approximately 90% when an optimal fixture was used with the ideal welding method. Thus, time and cost savings were achieved in complex welding manufacturing processes.