Issues such as plastic deformation control, residual stress and crevice corrosion exist when the expansion welding process is used to install the heat exchange tubes and tube plates in shell-and-tube heat exchangers. This paper focuses on the mechanical behavior of the heat exchange tubes under the expansion welding process. Using 304 stainless steel and Q245R carbon steel as research materials, the study was conducted through a combination of experiments and simulations. The expansion welding experiment of the heat exchange tubes was designed based on actual working conditions. The relationship between the expansion rate and the equivalent strain was obtained using the electrical measurement method, and a mathematical model of equivalent stress and expansion rate was established, which enables stress prediction during the expansion process. The distribution law of residual stress on the surface of the heat exchange tubes after expansion welding is presented. The results show that the extreme values of residual stress and the maximum stress gradient both occur near the end of the expansion welding area, and this area should be given special attention.
Key words
Heat exchanger /
Expansion process /
Residual stress /
Q245R carbon steel /
304 stainless steel
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