Leading-edge weld-modeling methodologies.
Thanks in large part to the sponsorship of the Battelle Joint Industry Program (Battelle JIP), rapid progress has been made in further refining and validating the effectiveness of the structural stress method of weld-fatigue analysis. In the process, the Battelle JIP team has effectively correlated large quantities of S-N data from drastically different joint types, loading modes and plate thicknesses.
The Challenge & Solution
Math-based manufacturing welding remains a primary fabrication and assembly process. With today’s increasing demands for improved product quality and reduced manufacturing costs, math-based rapid virtual prototyping techniques have become essential for integrating materials, manufacturing, product design and performance.
Conventional, commercially-available CAE/CAM simulation tools, however, are not able to address all the manufacturing concerns that impact the performance of welded structures.
The solution is a tool that considers:
- Welding-induced residual stress
- Weld-property variation
- Weld-design parameters
The Virtual Welding Laboratory
Over the years, Battelle’s Center for Welded Structures Research has developed a unique suite of advanced and fully integrated computational simulation tools. These tools have proven to be highly effective in not only troubleshooting on the production floor, but also as new-product-development aids in the areas of weld-design optimization, weldability, characterization, welding-procedure development, and performance evaluation.
Because these tools are modular, they support portability and smooth interface with commercial finite-element codes. And because they can be used in conjunction with Battelle’s design and manufacturing expertise, they represent a cost-effective means of addressing the design and manufacturing concerns associated with both solid-state-joining and fusion-welding processes.
These simulation tools support:
- Solid-state joining processes, including resistance, friction/inertia, and friction stir welding, with tools such as a novel electrode design, process-parameter optimization, residual stress/distortion mitigation, weld-performance prediction and optimization
- Arc welding and high-energy beam welding, via weld and fixturing design, weld-pool modeling for monitoring/control, a residual stress/distortion mitigation technique, and optimum weld-sequencing development
- Optimum joint design and performance evaluation, through fatigue-resistant joint design, fatigue-life prediction methodologies, fracture control, and fitness-for-service assessment incorporating advanced residual stress techniques as well as mechanical and thermal stress improvement techniques such as optimized post-weld heat treatment (PWHT) and local post-weld heat treatment (L-PWHT).
Sequential Manufacturing Processes
Product performance can be vastly improved by considering the interactions of sequential manufacturing processes for specific applications. The combined impact of these processes can be evaluated at either a local or global weld level for optimized structural performance.
Battelle can help you optimize: