Redistribution of Residual Stresses in Titanium Alloy Butt-Welded Thick Plates Due to Wire-Cut Electrical Discharge Machining

Welding and cutting behaviour may affect the mechanical properties of titanium alloy welded structures, which may have some impact on the safety assessment of the structure. This study analyses changes in residual stress in Ti80 butt-welded thick plates before and after wire-cut electric discharge machining, using numerical simulations based on thermo-elastoplastic theory and the element birth and death method, validated by X-ray non-destructive testing. The transverse residual tensile stress near the weld exhibits an asymmetric bimodal distribution, while the longitudinal stress is significantly higher than the transverse stress. Wire-cut electric discharge machining had minimal influence on the transverse residual stress distribution but led to partial relief of the longitudinal residual tensile stress. The maximum reductions in transverse and longitudinal welding residual tensile stresses are approximately 60% and 36%, respectively. The findings indicate that wire-cut electric discharge machining can alter surface residual stresses in Ti alloy butt-welded thick plates. This study also establishes a numerical simulation methodology for analysing welding residual stresses and their evolution due to wire-cut electric discharge machining. The results provide a theoretical basis for analysing the structural strength and safety of Ti-alloy-based deep-sea submersibles.