Exploring a Complex Weld Design Space using a Large Number of Computational Weld Mechanics Analysis, Time Effective – CWA Journal, April 2017


    The physics and mechanics of welding can be separated into the physics of the arc and weld pool on the one hand and the mechanics of the solid base metal on the other hand. The coupling between the physics and mechanics of the weld pool and the solid base metal is mainly Computational Weld Mechanics’ (CWM) algorithms and software that predict the behavior of welds in the welded structures.

    Development of CWM started in the early 1970s for practical weld engineering and it is now maturing with a good level of reliability, including complex physics of welding, material modeling, and stress-strain dependency on temperature and evolution of microstructure. Recent activities have focused on computational strategies and how they are integrated with other approaches to facilitate the use of simulations in industrial scale engineering with sizeable geometry and real-world complexity. Available modeling packages of the welding process solve the welding process based on 3D transient nonlinear finite element analysis (FEM) with realistic 3D geometry using complex numerical algorithms and are often solved for thousands of time steps associated with the welding progress.
    A CWM package can save time, money and explore “what if” scenarios that are difficult to assess by analytical approaches, and/or through experimentation alone. A CWM package can be viewed as a control box that has a set of output responses associated to a set of input parameters. The input parameters can be welding parameters e.g. weld power, weld speed, sequencing, etc or parameters associated with the welded structure such as geometrical dimensions, weld location, weld size, fixturing, and more, or workmanship factors such as welding flaw, cracking, randomness, and so on.
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