Dear scholars,

my topic of interest is the numerical analysis of weldments with special interest in material heterogeneitiy (base material, coarse- & fine-grain-zone, filler material). For this purpose, i modeled a quarter of a 3D-butt-welded sample under displacement load. Each particular zone was modelled with specific material-data (for all in general: multilinear-plasticity; isotropic hardening), Hollomon-extrapolation was used to obtain realistic results.

The results of the numerical simulation show huge discontinuities in zones of material transition when it comes to the internal stresses (for von-Mises-stress, see the attached PDF). In my opinion, these discontinuities have their origin in the simple fact, that the nodes on the borders between two different materials can't "smooth out" the two differing material behaviours. This arises from the fundamentals of FEA and can't be "improved" by ANSYS-specific modelling steps.

Am I right with my conclusion or does anyone have any advice for me in this context? Any advice is highly appreciated. In case there are still questions, I have attached my APDL script. Otherwise don't hesitate to ask, if more information is needed.

The basic facts of my numerical approach:

- Calculation using APDL script in ANSYS

- Notch stress analysis on 2D/3D bodies

- Meshed with quadratic elements

>>> 2D: Plane183

>>> 3D: Solid186 & Solid 187

- Multilinear-plasticity material models with isotropic hardening

- Due to lack of experimental data: stress-strain diagrams of the 4 material domains from secondary source.

>>> Hollomon extrapolation already performed there

Many thanks for any help.

Timo Siemer

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