Three Dimensional Finite Element Analysis of Weld Overlay Application on a Plastically Formed Feeder Tube

Abstract

This paper presents a finite element analysis (FEA) model to predict the residual stresses in a tight-radius warm bend feeder tube in a CANDU nuclear reactor coolant system throughout the various stages of the manufacturing and welding processes, including feeder tube forming, Grayloc hub weld, and weld overlay application. The FEA employs 3-D elastic-plastic technology with large deformation capability to predict the residual stresses due to the feeder tube forming and various welding processes. The results demonstrate that the FEA method captures the residual stress trends resulted from warm bending and weld overlay with acceptable accuracy.