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All Journal Journal of Welding Technology
Regan Rahadian Pambudi
PEM Akamigas
Industrial & Manufacturing Engineering Materials Science & Nanotechnology Mechanical Engineering

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Numerical framework for multi-pass SMAW pre-WPS development on SA-36 low carbon steel Regan Rahadian Pambudi; Ayende Ayende
Journal of Welding Technology Vol 8, No 1 (2026): June
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jowt.v8i1.9252

Abstract

Multi-pass SMAW on low carbon steel demands precise parameter control to ensure joint integrity and qualification compliance. Trial-and-error WPS development is material-intensive and time-consuming, particularly where heat input management across passes is critical. This study proposes a numerical framework combining Carbon Equivalent (CET) analysis, Rosenthal 2D thermal modeling via MATLAB with SmartWeld suite, and thermo-mechanical FEA to determine preliminary welding parameters prior to experimental qualification. Parameters are validated on SA-36 plate using a 4-pass SMAW procedure qualified under ASME BPVC Section IX, with NDT per ASME BPVC Section V. Tensile strengths of 530.90 MPa and 503.99 MPa exceed the 400 MPa minimum, all bend specimens pass without rejectable discontinuities, and FEA deformation prediction of 1.59 mm against a measured 2.01 mm demonstrates conservative predictive capability suitable for preliminary parameter screening. Unlike conventional trial-and-error qualification, this framework integrates three analytical methods into a structured pre-screening workflow, reducing material consumption and qualification iterations prior to experimental testing.
Comparison of electrode diameter-based and heat input-based methods for estimating the number of weld passes in shielded metal arc welding (SMAW) Susilo Handoko; Regan Rahadian Pambudi
Journal of Welding Technology Vol 8, No 1 (2026): June
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jowt.v8i1.9616

Abstract

Selecting the appropriate number of weld passes is an important step in Shielded Metal Arc Welding (SMAW) because it influences weld quality, heat input, productivity, and metallurgical characteristics of the welded joint. Existing approaches, such as the heat input-based procedure proposed by Trindade, provide reliable estimates by considering welding heat input and allowable thermal limits but require detailed welding parameters that are often unavailable during the initial stage of welding procedure planning or impractical to calculate on the production floor. This study proposes a simplified empirical equation for estimating the required number of SMAW weld passes using only plate thickness and the smallest electrode diameter. The proposed equation was evaluated by comparison with a modified heat input-based procedure derived from Trindade and integrated with EN 1011-2:2001 through Carbon Equivalent (CET) assessment. The comparison was conducted for single V-groove butt joints in the 1G position using a 2.6 mm E7016 electrode on plate thicknesses of 5, 8, 10, 12, and 16 mm. The proposed method predicted 2, 4, 4, 5, and 7 weld passes, whereas the modified heat input method required 2, 4, 6, 8, and 15 passes, respectively. Both methods produced identical results for plate thicknesses up to 8 mm; however, the discrepancy increased for thicker plates because the proposed equation does not account for groove geometry, welding travel speed, deposition rate, or heat input. The results demonstrate that the proposed equation provides a rapid and practical preliminary estimation tool for low-thickness SMAW joints, enabling fabrication personnel to estimate the required number of weld passes within seconds using only readily available parameters before detailed heat input verification is performed.
Comparative finite element analysis of IIW linear stress extrapolation and haibach methods for structural hot-spot stress prediction in welded plate joints Regan Rahadian Pambudi; Richard Alexander
Journal of Welding Technology Vol 8, No 1 (2026): June
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jowt.v8i1.9504

Abstract

Accurate prediction of structural hot-spot stress (SHSS) is essential for evaluating welded joints. This study compares the International Institute of Welding (IIW) Linear Stress Extrapolation (LSE) and Haibach methods using finite element analysis performed with the open-source software CalculiX. Three weld geometry representations (no weld, chamfer, and fillet) and two mesh densities (fine and coarse) were investigated, resulting in six finite element models. Both SHSS methods were applied to evaluate stress prediction, mesh sensitivity, weld geometry effects, and computational performance. The IIW LSE method consistently predicted higher SHSS than the Haibach method, while mesh refinement produced variations below 4%. In contrast, weld geometry had a greater influence on SHSS prediction, with the chamfer model producing the highest stress. Fine meshes required approximately five to six times longer computational time than coarse meshes while providing only marginal improvements in SHSS prediction. Weld geometry representation was therefore found to have a greater influence on SHSS prediction than mesh density. The IIW LSE method is recommended for conservative structural assessment, whereas the Haibach method is suitable for preliminary engineering analyses requiring simpler post-processing.
Co-Authors Ayende Ayende Richard Alexander Susilo Handoko