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Abstract
Effect of preheat on the thermal cycles, residual stress, and distortion during autogenous GTA welding of Grade P91 steel has been analyzed using FEM. Phase transformation effect on the residual stresses is also analyzed. Thermomechanical analysis has shown that preheat reduced the peak temperatures, cooling rate, and the distortion values. The phase transformation involving martensite during cooling resulted in typical “M” shaped residual stress profile with a reduction in peak tensile residual stress value and a wider distribution of residual stress. There is good agreement between the predicted and measured thermal cycles, residual stresses, and distortion of the P91 steel weld joint.