Optimization of welding parameters on welding distortion and stress in S690 high-strength steel thin-plate structures

This study examines the impact of welding heat input on the residual stress and welding deformation of large, thin-walled constructions made of ultra-high strength steel using a single shot calculation method. These structures are susceptible to warpage distortion after welding, which negatively affects production precision. The study uses an interactive orthogonal experimental design to optimize welding parameters and investigate their influence on deformation. Results reveal that welding speed has the most significant impact on deformation, followed by welding voltage and current. The optimal welding parameters (v = 60 cm/min, I = 160 A, U = 16 V) are validated through simulation and experiment, which reduce deformation by 5.4%. After optimization, the pump arm's side bending volume and warpage volume decrease by 4.06% and 9.56%, respectively, and welding deformation significantly reduces. Experimental verification shows a maximum error of 2.6%, indicating the accuracy of the finite element model. This study provides a theoretical basis for improving the performance of welding large, thin-walled box structures.