In the present study, Manual Metal Arc Welding (MMAW) of austenitic stainless steel to carbon steel were studied. The Schaeffler diagram were used in determining suitable filler metal for this process and then the finite element analysis of residual stresses in butt welding of two dissimilar pipes is performed with the commercial software ANSYS, which includes moving heat source, material deposit, temperature dependant material properties, metal plasticity and elasticity, transient heat transfer and mechanical analysis. The residual stresses distribution and magnitude in the hoop and axial directions in the inner and outer surfaces of two dissimilar pipes were obtained.
Welding simulation considered as a sequentially coupled thermo-mechanical analysis and the element birth and death technique was employed for simulation of filler metal deposition.