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Fem Analysis of Residual Stresses in Welded Aluminum and Polyamide 6 Cover

Fem Analysis of Residual Stresses in Welded Aluminum and Polyamide 6

Open Access
|Oct 2025

Figures & Tables

Figure 1.

The effect of thermal bending.
The effect of thermal bending.

Figure 2.

Railroad tracks bent due to linear thermal expansion (image source: https://thermtest.com/what-is-coefficient-of-thermal-expansion-how-to-measure-it).
Railroad tracks bent due to linear thermal expansion (image source: https://thermtest.com/what-is-coefficient-of-thermal-expansion-how-to-measure-it).

Figure 3.

Resistance Welding Station.
Resistance Welding Station.

Figure 4.

The process curve for fabrication (Zhang et al., 2023).
The process curve for fabrication (Zhang et al., 2023).

Figure 5.

AL-CPA6 RW Sample.
AL-CPA6 RW Sample.

Figure 6.

Deflected sample.
Deflected sample.

Figure 7.

CAD model of the welded sample.
CAD model of the welded sample.

Figure 8.

Pressure application in the model.
Pressure application in the model.

Figure 9.

Closeup of the FEM mesh.
Closeup of the FEM mesh.

Figure 10.

Isotropic secant coefficient of the thermal expansion of Aluminum 7075 (Rice et al., 2011).
Isotropic secant coefficient of the thermal expansion of Aluminum 7075 (Rice et al., 2011).

Figure 11.

Influence of temperature on the isotropic elasticity of Aluminum 7075 (Rice et al., 2011).
Influence of temperature on the isotropic elasticity of Aluminum 7075 (Rice et al., 2011).

Figure 12.

Stress–strain relationship of Polyamide 6 samples (Farina et al., 2019).
Stress–strain relationship of Polyamide 6 samples (Farina et al., 2019).

Figure 13.

Thermal analysis, maximum temperature output.
Thermal analysis, maximum temperature output.

Figure 14.

Residual Stress. Von Mises plot (20°C→240°C→20°C).
Residual Stress. Von Mises plot (20°C→240°C→20°C).

Figure 15.

End of time, residual shear stress. Overall plot (20°C→240°C→20°C).
End of time, residual shear stress. Overall plot (20°C→240°C→20°C).

Figure 16.

End of time, residual normal stress. Overall plot (20°C→240°C→20°C).
End of time, residual normal stress. Overall plot (20°C→240°C→20°C).

Figure 17.

End of time, residual shear stress. Weld area plot, aluminum surface (20°C→240°C→20°C).
End of time, residual shear stress. Weld area plot, aluminum surface (20°C→240°C→20°C).

Figure 18.

End of time, residual normal stress. Weld area plot aluminum surface (20°C→240°C→20°C).
End of time, residual normal stress. Weld area plot aluminum surface (20°C→240°C→20°C).

Figure 19.

Residual Stresses on the Weld Path.
Residual Stresses on the Weld Path.

j_jvetres-2024-0060_utab_001

SymbolDescriptionUnit
ΔLChange in length due to thermal expansionmm
LOriginal lengthmm
αLLinear coefficient of thermal expansion (CTE)[-]
ΔTTemperature change°C or K

j_jvetres-2024-0060_utab_002

σThermal stressMPa
EYoung’s modulusMPa

The sample dimensions_

SampleLength L [mm]Join Length [mm]Width [mm]Thickness AL. [mm]Thickness CF [mm]Thickness [mm]delta (deflection [mm])
1110272511.82.82.2
2110272511.82.82.3
3110272511.832.9
4110272511.834
5110272511.834.4
6110272511.832.2
7110272511.833.6
8110272511.833.7
DOI: https://doi.org/10.2478/fas-2024-0005 | Journal eISSN: 2300-7591 | Journal ISSN: 2081-7738
Language: English
Page range: 57 - 74
Published on: Oct 14, 2025
Published by: ŁUKASIEWICZ RESEARCH NETWORK – INSTITUTE OF AVIATION
In partnership with: Paradigm Publishing Services
Publication frequency: 1 issue per year

© 2025 Marcin Praski, Piotr Kowalczyk, Radosław Szumowski, Karolina Stankiewicz, Andrzej Leski, published by ŁUKASIEWICZ RESEARCH NETWORK – INSTITUTE OF AVIATION
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.