Large-dimension complex integral thin-shell components are widely used in advanced transportation equipment. However, with the dimensional limitations of raw blanks and the manufacturing process, there are inhomogeneous geometric and mechanical properties at welded joints after welding, which have a significant effect on the subsequent forming process. Therefore, in this paper, the microstructure of welded joints with a sharp property change was accurately characterized by the proposed isothermal treatment method using the BR1500HS welded tube as an example. In addition, an accurate constitutive model of welded tubes was established to predict the deformation behavior. Firstly, the heat-treated specimens were subjected to uniaxial tensile tests and the stress-strain curves under different heat treatment conditions were obtained. Then, the continuous change in flow stress in the direction of the base metal zone, the heat-affected zone and the weld zone was described by the relationship between the microhardness, flow stress and center angle of the welded tube. Using such a method, a continuous constitutive model of welded tubes has been established. Finally, the constitutive model was compiled into finite-element software as a user material subroutine (VUHARD). The reliability of the established constitutive model was verified by simulating the free hydro-bulging process of welded tubes. The results indicated that the continuous constitutive model can well describe the deformation response during the free hydro-bulging process, and accurately predicted the equivalent strain distribution and thickness thinning rate. This study provides guidance in accurately predicting the plastic deformation behavior of welded tubes and its application in practice in hydroforming industries.
Keywords: FE simulation; continuous constitutive model; digital image correlation; free hydro-bulging; welded tube.