Summary
This paper describes application of the thermal elastic‐plastic FEM method to analyse three‐dimensional residual stresses in single‐pass and multi‐pass fillet welds. The inherent strains generated in the fillet welds are expressed by series functions with good accuracy. Based on the results of the series functions, an extremely simple inherent strain distribution pattern is proposed and functionally represented with few unknown coefficients. This approach significantly reduces the number of measurements required to determine these unknown coefficients.