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Battelle Welding Technology Helping Manufacturers Save Money

Posted on Apr 26, 2012

COLUMBUS, OH., 26 April, 2012—The latest spot weld reliability assurance technology, developed exclusively by Battelle, has been adopted for use by Safe Technology’s fe-safe® suite of software for fatigue analysis from finite element models.

It is a complimentary tool to be used with Verity®, another Battelle-developed fatigue analysis tool that is also licensed to Safe Technology.  The revolutionary Verity® mesh insensitive structural stress method uses new patented methods to accurately calculate the fatigue lives of welded joints by eliminating the uncertainty of traditional methods.

In the early ’90s, Battelle scientists recognized the need for a reliable stress analysis methodology that would address the known problems encountered in conventional finite element analysis procedures for welded joints and other geometric discontinuities. Consequently, Battelle created, developed and validated a new methodology known as the Verity® mesh-insensitive structural stress methodology. Although initially viewed as "too good to be true" or "too simple to possibly work," Verity® has now been validated by leading industry experts across a broad array of industries, and has been adopted by respected codes and standards organizations.

The new spot weld modeling procedure calculates reliable structural stresses consistent with the Verity® master S-N curve. As such, no additional fatigue data are needed to apply this new approach to wide range of spot welding techniques.  Moreover, the new spot weld model is simpler to apply and more computationally efficient, and thus enables greater numbers of spot welds to be analyzed with existing facilities, said Jeong K. Hong, a Battelle technical lead who developed the process.

The fe-safe tool, with spot welding capabilities, can accelerate new product introduction and reduce cost when integrated into the design process. It’s primarily being used by the automotive industry and has potential applications everywhere spot welds are used. The fe-safe spot weld module automatically detects the number of sheets welded together, the thickness of each sheet, and the location of each spot weld. Very short analysis times are obtained even with models that contain many thousands of spot welds. The software works with beam elements and also with Abaqus connector elements.

“We’re pleased to add the new spot welding capability to our Verity suite of fatigue analysis tools. We’re continually trying to offer our customers more tools that will help them save time and money in the complex business of fatigue analysis,” said John Draper, Safe Technology’s CEO.

About Battelle

As the world’s largest independent research and development organization, Battelle provides innovative solutions to the world’s most pressing needs through its four global businesses:  Laboratory Management; National Security; Health and Life Sciences; and Energy, Environment and Material Sciences. It advances scientific discovery and application by conducting $6.2 billion in global R&D annually through contract research, laboratory management and technology commercialization. 

Headquartered in Columbus, Ohio, Battelle oversees 22,000 employees in more than 130 locations worldwide, including eight national laboratories for which Battelle has a significant management role on behalf of the U.S. Department of Energy, the U.S. Department of Homeland Security, and the United Kingdom.

Battelle also is one of the nation’s leading charitable trusts focusing on societal and economic impact and actively supporting and promoting science, technology, engineering and mathematics (STEM) education.

Media Contacts

For more information contact Katy Delaney at (614) 424-7208 or, or T.R. Massey at (614) 424-5544 or


Media Contacts

Katy Delaney
Director, Media Relations
Office: 1.614.424.7208

T.R. Massey

Senior Media Specialist
Office: 1.614.424.5544