Aero-engine blisk welded by electron beam welding（EBW） method is a complicated structure. Fixtures were used to control the deformation of blisk during its manufacturing process. Finite element method was utilized to study the evolution of the welding residual stress and deformation of this structure. In which an attenuation function was applied to the double ellipsoid heat source model based on the characteristic of EBW, and the effects of fixtures on the welding residual stresses and deforamtion were also reserached. The simulation results showed that the temperature contour of weld cross section vertical to the weld centerline followed a ＇＂ V＂ shape. Moreover, large welding residual stress and distortion were found in the interface between blisk and fixtures. The stress concentration was reduced sufficiently in starting and end part of weldment as the fixtures were renmved after welding process, while the removing operation had almost no effects on the welding residual stress in the middle section of weld bead.
In order to improve aero engine performance, it is necessary to reduce the welding residual stress of aero engine blisk. In this paper, finite element method was employed to simulate electron beam welding process of blisk, in accordance with the deducing formula（ p = kh ） , the heat input is changed with the weld depth to control welding residual stress of blisk. The calculation results show that welding residual stress of blisk can be controlled effectively by reducing the heat input on the conditions of meeting the demand of weld penetration and guaranteeing the welding quality, a new theoretical method and some numerical data are provided for controlling welding residual stress of blisk.
