Multiscale process simulation of residual stress fields of laser beam welded precipitation hardened AA6082

In this study, a multiscale modelling approach for the determination of residual stresses for the laser beam welded, precipitation hardened aluminium alloy AA6082-T6 is presented and applied. The material behaviour is described by an elasto-visco-plastic material model, specially suited for fusion welding processes. The microstructure evolu- tion during the welding process has a direct influence on the macroscopic mechanical properties. The modelling approach accounts for the change in the microstructure via a Kampmann–Wagner Numerical model which takes into account the kinetics of the precipitates. The macroscopic mechanical properties are determined via classic dislocation theory, which accounts for the interaction between dislocations and precipitates. The temperature field of the welding process is described by a highly efficient semi-analytical approach. The solution of the tem- perature field in connection with a three dimensional moving heat source is achieved by using the method of Green’s functions. By employing the method of Green’s functions, it is possible to reduce the numerical effort significantly. The results of this modelling approach are compared to temperature, hardness as well as residual stress measurements, obtained from synchrotron X-ray diffraction, for welded sheets to clarify the accuracy of the applied model