Numerical Simulation and Experimental Investigation of Residual Stress and Distortion in the Repair Welding of a Gas Turbine Nozzle Guide Vane

Articles in Press

Document Type : Research Paper

Authors
Mohammad Sajad Rabie Zadeh 1
Esmaeil Hajjari 1
Seyed Mohammad Lari Baghal 1
Ahmad Firouzian-Nejad 2
1 Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran
2 National Iranian South Oil Company (NISOC), Ahvaz, Iran
10.22055/jacm.2026.49060.5712
Abstract
Residual stress and distortion are two important problems that usually arise during the welding of complex industrial components. In this research, the effects of welding heat input, preheating temperature, and mechanical restraints (clamps) on residual stress and distortion in the repair welding of a gas turbine nozzle guide vane are studied through numerical analysis and experimental evaluations. To validate the numerical simulation results, a gas turbine nozzle is practically welded, and the temperature, residual stresses, and distortion are measured experimentally. The simulation results indicate that welding heat input has a significant effect on the distribution of residual stresses. It is observed that preheating does not considerably affect residual stresses, and increasing the preheat temperature leads to an increase in the total distortion of the component. Due to the complex and non-symmetrical geometry of the gas turbine nozzle, using clamps as mechanical restraints does not decrease distortion, but, in most cases, causes an increase in both residual stresses and distortion. The temperature and stress distribution results reveal that the maximum tensile residual stress at the trailing edge adjacent to the weld zone is close to (or exceeds) the yield stress of the base metal. This area experiences a temperature above half of the alloy's melting point, which can satisfy the cracking conditions and lead to the development of liquation and ductility dip cracks.
Keywords
Numerical Simulation
Repair Welding
Gas Turbine Nozzle Guide Vane
Residual Stresses
Distortion
Subjects

Publisher’s Note Shahid Chamran University of Ahvaz remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

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Journal of Applied and Computational Mechanics

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Available Online from 23 June 2026