An Experimental and Numerical Investigation of Distortion and Residual Stress in GTAW Dissimilar Pipe Welds

Hamdani; Akhyar; Thaib Rizwan; Agus Sasmito

doi:10.48084/etasr.18937

Authors

Hamdani School of Engineering, Universitas Syiah Kuala, Banda Aceh, Indonesia | Department of Mechanical Engineering, Politeknik Negeri Lhokseumawe, Lhokseumawe, Indonesia https://orcid.org/0009-0007-6346-4303
Akhyar Department of Mechanical Engineering, Universitas Syiah Kuala, Banda Aceh, Indonesia
Thaib Rizwan Department of Capture Fisheries, Marine and Fisheries Faculty, Universitas Syiah Kuala, Banda Aceh, Indonesia
Agus Sasmito Research Center for Hydrodynamic Technology, National Research and Innovation Agency of Indonesia, Surabaya, Indonesia

Volume: 16 | Issue: 3 | Pages: 36559-36566 | June 2026 | https://doi.org/10.48084/etasr.18937

Received: 26 March 2026 | Revised: 3 May 2026 | Accepted: 8 May 2026 | Online: 6 June 2026
Corresponding author: Akhyar

Abstract

Welding dissimilar metals often results in complex thermo-mechanical behavior due to differences in material properties, which can lead to distortion and residual stress. This study evaluates the thermo-mechanical response of SUS304–SA213-T11 dissimilar pipe welds using a coupled numerical–experimental methodology. Gas Tungsten Arc Welding (GTAW) was performed with varying heat inputs, and a sequentially coupled finite element model was developed to predict temperature distribution, distortion, and residual stress. A dial gauge and the magnetic-based Stress Vision technique were used to take experimental measurements of deformation and residual stress. The findings indicate that with increasing welding current, the peak temperature and Heat Affected Zone (HAZ) area increase. Both deformation and residual stress decrease with increased current due to less heat accumulation caused by high travel speed. The highest deformation and residual stress occurred at 70 A, and the lowest at 90 A. The results stand as evidence that heat accumulation is the driving factor for the thermo-mechanical behavior of dissimilar pipe welds instead of current, thus elaborating a valuable insight to enhance welding parameters in industries.

Keywords:

dissimilar welding, residual stress, distortion, FEA, pipe welding

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