Experimental analysis and numerical simulation on residual stress and welding distortion of thin-gauge sheets for roof cover panel

Experimental analysis and numerical simulation on residual stress and welding distortion of thin-gauge sheets for roof cover panel | 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 Experimental analysis and numerical simulation on residual stress and welding distortion of thin-gauge sheets for roof cover panel Bengang Yi, Xiaobing Cao, Zhiqiang Sun, Haijie Feng, Pengfei Xie, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7339804/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract In this work, the simulations and welding experiments including RSW and MIG processes for concave-convex distortion (CCD) defects of roof cover panel have been conducted. The detailed discussions on the temperature, residual stress, and formation mechanism as well as critical conditions are comprehensively analyzed. The welding simulation results have a satisfactory precision and reliability to match with the RSW and MIG experiments. The spread distance of residual stress in RSW decreases as the flange length increases. The spread distance of MIG process is slightly less than the minimum distance of RSW process at the flange length of 32 mm. Suppressing the presence of compressive stress is the key approaches to eliminate the CCD defects of outer roof cover panel. When the welding compressive stress exceeds the critical instability stress of outer roof cover panel, the partial buckling distortion indicates a dent CCD defect. In addition, there is a positive relationship between compressive stress and heat input power during MIG process. The magnitude of CCD defects become more and more serious with the increase of the bead length from 5 mm to 20 mm. The critical conditions to maintain an excellent appearance quality for RSW and MIG are the flange length of 27 mm to 35 mm and the bead length of 5 mm to 10 mm, respectively. The optimum MIG process with the bead length of 8 mm indicates an intact appearance quality of roof cover panel. Concave-convex distortion Residual stresses Resistance spot welding Metal intert-gas welding Numerical simulation Full Text Cite Share Download PDF Status: Under Review Version 1 posted Editorial decision: Major Revisions Needed 31 Mar, 2026 Reviewers agreed at journal 22 Sep, 2025 Reviewers invited by journal 22 Sep, 2025 Editor assigned by journal 13 Aug, 2025 First submitted to journal 10 Aug, 2025 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. 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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-7339804","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":518600721,"identity":"f6e1c36f-4e4f-4a24-b9ee-c255f5474c9f","order_by":0,"name":"Bengang Yi","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Bengang","middleName":"","lastName":"Yi","suffix":""},{"id":518600722,"identity":"dbbc79db-4927-4c4e-af60-0f8d8b3b8471","order_by":1,"name":"Xiaobing 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panel","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Concave-convex distortion, Residual stresses, Resistance spot welding, Metal intert-gas welding, Numerical simulation","lastPublishedDoi":"10.21203/rs.3.rs-7339804/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7339804/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eIn this work, the simulations and welding experiments including RSW and MIG processes for concave-convex distortion (CCD) defects of roof cover panel have been conducted. The detailed discussions on the temperature, residual stress, and formation mechanism as well as critical conditions are comprehensively analyzed. The welding simulation results have a satisfactory precision and reliability to match with the RSW and MIG experiments. The spread distance of residual stress in RSW decreases as the flange length increases. The spread distance of MIG process is slightly less than the minimum distance of RSW process at the flange length of 32 mm. Suppressing the presence of compressive stress is the key approaches to eliminate the CCD defects of outer roof cover panel. When the welding compressive stress exceeds the critical instability stress of outer roof cover panel, the partial buckling distortion indicates a dent CCD defect. In addition, there is a positive relationship between compressive stress and heat input power during MIG process. The magnitude of CCD defects become more and more serious with the increase of the bead length from 5 mm to 20 mm. The critical conditions to maintain an excellent appearance quality for RSW and MIG are the flange length of 27 mm to 35 mm and the bead length of 5 mm to 10 mm, respectively. The optimum MIG process with the bead length of 8 mm indicates an intact appearance quality of roof cover panel.\u003c/p\u003e","manuscriptTitle":"Experimental analysis and numerical simulation on residual stress and welding distortion of thin-gauge sheets for roof cover panel","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-03 12:37:18","doi":"10.21203/rs.3.rs-7339804/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2026-03-31T22:02:09+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-09-22T12:57:52+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-09-22T09:08:57+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-08-13T07:14:08+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-08-10T11:45:53+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"4cf7a598-186d-44b4-a474-a48970212e02","owner":[],"postedDate":"October 3rd, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-05-04T05:18:26+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-03 12:37:18","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7339804","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7339804","identity":"rs-7339804","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}