In this paper, based on Simufact Welding finite element analysis software, a numerical simulation of the temperature and residual stress distribution of the weldolet-header multi-layer multi-pass welding process is carried out, and the simulation results are verified through experiments. The experimental results are in good agreement with the numerical simulation results, which proves the validity of the numerical simulation results. Through the results of the numerical simulation, the influence of the welding sequence and interlayer temperature on the temperature and residual stress distribution at different locations of the saddle-shaped weld was studied. The results show that the temperature and residual stress distribution on the header and weldolet are asymmetric, and the high-stress area of the saddle-shaped welded joint always appears at the saddle shoulder or saddle belly position. When the interlayer temperature is 300 °C, the peak residual stress reaches a minimum of 428.35 MPa. Adjusting the welding sequence can change the distribution trend of residual stress. There is no high-stress area on the first welding side of the two-stage welding path-2. The peak values of residual stresses for continuous welding path-1 and two-stage welding path-2 are 428.35 MPa and 434.01 MPa, respectively, which are very close to each other.

It is well known that welding dissimilar metals can play the advantages and characteristics of those different metals, but it is easy to encounter some problems. In this paper, the thermomechanical behavior of the weldolet–branch dissimilar steel joints in different welding cases is analyzed by establishing a three-dimensional finite element model, and the predicted thermal cycling and residual stresses are verified using experimental tools. The results show that the high temperature area and the heat affected zone on the side of the branch pipe are larger, and there is a large stress gradient at the fusion line on both sides of the weld. Too high or too low temperature between welding layers will cause large residual stress, thus, 200 °C is more suitable for the welding of weldolet–branch joints. The residual stresses of path-1, path-2 and path-3 have similar distributions at 0° and 180° sections, and the circumferential and axial residual stresses on the inner surface are larger than those on the outer surface. The residual stress on the inner and outer surfaces of path-3 is smaller than that of path-1 and path-2 at the 90° and 270° sections as a whole, and the residual stress at the 90° section reaches the minimum.