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All Journal International Journal of Marine Engineering and Applications
Alfian Nur Pratama
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Control & Systems Engineering Energy Engineering Mechanical Engineering Transportation

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CFD SIMULATION OF THERMAL CHARACTERISTICS IN T-JOINT WELDING TO PREDICT INCOMPLETE FUSION DEFECTS Alfian Nur Pratama; Hardianto, Didik; Kristiyono, Tri Agung
IJMEA International Journal of Marine Engineering and Applications Vol 3 No 2 (2026): September 2026
Publisher : Department of Marine Engineering, Universitas Hang Tuah

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30649/ijmea.v3i2.409

Abstract

Welding is a critical process in marine and shipbuilding structures, particularly in T-joint configurations. However, uneven heat distribution during the fluid phase of welding often leads to incomplete fusion at the weld root. This study analyzes the thermal-mechanical characteristics of S50C medium carbon steel T-joint welding using Computational Fluid Dynamics (CFD) with a sequential thermal-structural finite element approach. The numerical model was discretized into a refined mesh configuration with 2,635 nodes and 660 elements. To model the residual thermal load from the CFD fluid phase, a constant thermal boundary condition of 400°C was applied as a ramped load to three base plate surfaces. Simulation results showed extreme residual stress accumulation concentrated at the weld root area. Linear path analysis along the "Strain Check" line revealed a rapid stress gradient increase from -1749.4 MPa to 392.06 MPa. Normal stress parameters recorded maximum compressive stress of -2503 MPa and peak tensile residual stress of 580.58 MPa. Normal strain parameters recorded minimum compressive strain of -4.6037 × 10⁻³ mm/mm and peak tensile strain of 3.9789 × 10⁻³ mm/mm. The peak residual stress value exceeded the ultimate tensile strength of S50C steel (580.58 MPa > 460 MPa). This thermal residual stress excess provides scientific validation for predicting structural failure initiation and internal notches, aligning with the 66 mm incomplete fusion defect track found in laboratory macroetch testing.
Co-Authors Didik Hardianto Kristiyono, Tri Agung