Taraphdar P.K.; Mahapatra M.M.; Pradhan A.K.; Singh P.K.; Sharma K.; Kumar S.2025-02-17202011http://dx.doi.org/10.1177/1464420720930355https://idr.iitbbs.ac.in/handle/2008/2794Thick AISI 304L stainless steel plates were welded using the gas metal arc welding process, and through-thickness residual stresses were evaluated by finite element simulation and the deep hole drilling technique. 3D moving heat source-based thermo-mechanical models were implemented to evaluate through-thickness residual stresses. The effects of the weld groove geometries and external restraints on the pattern of through-thickness residual stresses were studied. The maximum magnitude of locked-in residual stresses was recorded beneath the top surface, at a depth of around 6 mm. In comparison to conventional weld groove, the narrow weld groove configuration exhibited a 20�40% reduction in peak residual stresses. A significant rise in residual stresses was observed in constrained welds. The effect of the yield strength of the filler material on the evaluation of the through-thickness residual stress distribution in the course of finite element modeling was illustrated. The evolution of through-thickness residual stresses was also assessed concerning each weld pass. � IMechE 2020.deep hole drilling; residual stress; thermo-mechanical analysis; thick multipass welding; Welding simulationArticle