A comprehensive review of residual stresses in carbon steel welding: formation mechanisms, mitigation strategies, and advanced post-weld heat treatment techniques

Abstract

Abstract Residual stresses are critical factors influencing the service performance, reliability, and durability of welded carbon steel joints. These stresses can affect the joint, susceptible to brittle fracture, fatigue failure, and stress corrosion cracking, particularly within the heat-affected zone (HAZ). These stresses result from uneven thermal expansion and contraction during welding, with thicker plates and constrained configurations being more susceptible. Post-weld heat treatment (PWHT) assumes a critical function in mitigating these stresses by tempering martensitic structures, refining microstructures, and enhancing mechanical properties such as toughness and ductility. This review examines the mechanisms driving residual stress formation, evaluates the effectiveness of PWHT techniques, and highlights advanced methodologies like neutron diffraction, computational modeling, and hybrid welding processes. While PWHT significantly alleviates residual stresses, complete stress elimination remains unattainable, emphasizing the need for innovative strategies such as hybrid welding methods, computational modeling, and advanced heat treatments. This work integrates metallurgical principles with experimental findings to provide a strategy for enhancing the performance and reliability of welded joints in critically demanding industrial applications.