Residual Stress and HAZ Behaviour in Thin-Walled AISI 304 Stainless Steel under Orbital TIG Welding: A Thermo-Mechanical Study Across an Eight-Level Welding Speed Range

Residual Stress and HAZ Behaviour in Thin-Walled AISI 304 Stainless Steel under Orbital TIG Welding: A Thermo-Mechanical Study Across an Eight-Level Welding Speed Range | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Residual Stress and HAZ Behaviour in Thin-Walled AISI 304 Stainless Steel under Orbital TIG Welding: A Thermo-Mechanical Study Across an Eight-Level Welding Speed Range Stefanos Gerardis, Maria Pappa, Dimitris Fasnakis, Stergios Maropoulos This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7074476/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study focuses on the effects of the welding speed on the heat affected zone (HAZ), residual stress and microstructural characteristics of thin-walled AISI 304 stainless steel orbital TIG-welded tubes. Welding speeds between 0.5 and 2.5 mm/s have been assessed based on an integrated experimental-numerical model that uses direct metallurgical measurements coupled with finite element method (FEM) simulations. Metallographic evaluation of the HAZ widths showed average deviation of less than 5 % in comparison to the corresponding FEM estimations in most speeds. The microstructural analysis revealed a definite relationship between thermal cycles and δ-ferrite dendrite coarseness hence showing a connection between weld speed and solidification behaviour. FEM-derived residual stress patterns were found to be non-linear in terms of velocity; best mechanical and microstructural performance was found at 2.3 mm/s. The results also demonstrate the importance of fine speed resolution and confirm the use of FEM as a reliable predictive tool of thermal and mechanical effects of precision TIG welding applications. Orbital Welding TIG Welding AISI 304 Stainless Steel Welding Speed Heat-Affected Zone (HAZ) Residual Stress Full Text Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7074476","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":486822301,"identity":"3e612a7a-b94c-4527-b2b8-737ee924fbaa","order_by":0,"name":"Stefanos Gerardis","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAwElEQVRIiWNgGAWjYPACZh4G9gaStfAcIFELA4NEApFq5fsXH/vwc4+1jPzMN4aPeXMY7LYTcqDBjWfJM3uepfMY3M4xNubdxpA8h5ADDSTOGAO9cZjHQDrHTDoXqEWCoMNmnP/M+AeoRX7mGSK1MJzvYWYG2cJwgwesxY6gFoMbbMbMMgeAfjmTVmz8d5tEAmGH9R9+zPjmgLW9fPvhjQ9nbrOxJ+wwtOiQSGwgqIX/ACrfnqCOUTAKRsEoGHEAABOKOzMzf0MaAAAAAElFTkSuQmCC","orcid":"https://orcid.org/0000-0003-1991-5756","institution":"UOWM: Panepistemio Dytikes Makedonias","correspondingAuthor":true,"prefix":"","firstName":"Stefanos","middleName":"","lastName":"Gerardis","suffix":""},{"id":486822302,"identity":"2e94ac7d-0047-4340-a80e-22bff41e38c1","order_by":1,"name":"Maria Pappa","email":"","orcid":"","institution":"Aristotle University of Thessaloniki: Aristoteleio Panepistemio Thessalonikes","correspondingAuthor":false,"prefix":"","firstName":"Maria","middleName":"","lastName":"Pappa","suffix":""},{"id":486822303,"identity":"fa580451-2d07-4ca2-8755-176d4cb7c3a7","order_by":2,"name":"Dimitris Fasnakis","email":"","orcid":"","institution":"UOWM: Panepistemio Dytikes Makedonias","correspondingAuthor":false,"prefix":"","firstName":"Dimitris","middleName":"","lastName":"Fasnakis","suffix":""},{"id":486822304,"identity":"c1316fb2-3408-4d30-9d45-f4ec22cf4450","order_by":3,"name":"Stergios Maropoulos","email":"","orcid":"","institution":"UOWM: Panepistemio Dytikes Makedonias","correspondingAuthor":false,"prefix":"","firstName":"Stergios","middleName":"","lastName":"Maropoulos","suffix":""}],"badges":[],"createdAt":"2025-07-08 11:49:29","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7074476/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7074476/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":89448265,"identity":"e23bd641-b813-43a3-8dba-ee7dae2622b3","added_by":"auto","created_at":"2025-08-20 05:40:23","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1626730,"visible":true,"origin":"","legend":"","description":"","filename":"Gerardis2025WeldingHAZResStress.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7074476/v1_covered_b452ccda-6ddd-41dc-b750-73c22ecd9838.pdf"}],"financialInterests":"","formattedTitle":"Residual Stress and HAZ Behaviour in Thin-Walled AISI 304 Stainless Steel under Orbital TIG Welding: A Thermo-Mechanical Study Across an Eight-Level Welding Speed Range","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Orbital Welding, TIG Welding, AISI 304 Stainless Steel, Welding Speed, Heat-Affected Zone (HAZ), Residual Stress","lastPublishedDoi":"10.21203/rs.3.rs-7074476/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7074476/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study focuses on the effects of the welding speed on the heat affected zone (HAZ), residual stress and microstructural characteristics of thin-walled AISI 304 stainless steel orbital TIG-welded tubes. 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