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In-service welding simulations were carried out using a multiphysics finite element analysis (FEA). Calculated data as temperature and thermal cycles were validated by comparing them with experimental welding results carried out in a carbon steel pipe attached to a water loop. Two in-service welding cases were tested using the GMAW-P process with and without the assistance of induction preheating. The molten zone of weld macrographs and the simulated models were matched with excellent accuracy. The great agreement between the simulation and experimental molten zone generated a maximum error in the peak temperature of 1%, while in the cooling curve, the error was about 10% at lower temperatures. A higher hardness zone appeared in the weld’s toe within the CGHAZ, where the maximum induction preheating temperature achieved was 90°C with a power of 35 kW. Induction preheating reduced the maximum hardness from 390 HV to 339 HV. 

In most cases, in-service welding is susceptible to a higher using a multiphysics finite element analysis (FEA) coupling heat transfer, fluid flow, and electromagnetic heating. Part 1 presents the software implementation and model equations beside the mesh setting and modeling approach to simulate circumferential welding of Type B sleeve repair. The simulation was divided into four steps running sequentially for each physic solved in the model. Induction preheating was simulated and validated by comparing simulated temperature with experimental measurements. The multiphysics model differs from the usual simulations present in the literature, expressing more reliability in the results and making way for more-complete modeling for in-service applications.