SORPAS® 2D.welding

SORPAS® is dedicated professional software for resistance welding simulation and optimization of resistance welding processes. It has been specially developed for engineers by engineers for welding simulations. It doesn’t need any prior knowledge in numerical simulations, but can be easily learned and used by engineers with knowledge of welding and materials. The integration of welding expertise with numerical techniques has made SORPAS® a unique and powerful tool for engineers directly working in industry.

SORPAS 2D interface

“We have been using SORPAS® since 2001 and have made many innovative developments in resistance welding. We are now further extending the applications of simulation to process optimization for supporting production planning.”

– Mr. Matthias Graul, Volkswagen AG, Germany

The build-in material database in SORPAS® has included nearly all commonly used metal materials including all types of steels, aluminum alloys, titanium alloys, copper alloys, nickel based alloys, surface coating materials, pure metals and high melting metals such as tungsten and molybdenum etc. The users can also add their own materials. It is possible to simulate with dimensions of weld parts ranging from ordinary sizes in millimeters down to micro sizes in a fraction of micron with welding machines of all types of power sources including AC, DC, MFDC, inverter, and capacitor discharge.

Functions

SORPAS 2D.welding soultion - excel batch simulation

Excel batch planning

SORPAS provides an efficient way of optimizing welding process parameters for many weld points.

SORPAS 2D.welding soultion - intelligent weld planning

Intelligent weld planning

We provide fully automated weld planning function to optimize welding parameters and predict expulsion limit.

SORPAS 2D.welding soultion - process optimization

Process optimization

SORPAS predicts range for your task and makes an overview with weld growth curves and weldability lobes.

Export functions

SORPAS provides export for several other software.

Applications

SORPAS® has been applied in various industries for solving problems in spot welding, projection welding, butt welding and micro resistance welding and supporting research and development as well as process parameter optimizations.

SORPAS 2D welding simulation result with real test
  • Evaluating weldability of materials
  • Evaluating design of weld combinations
  • Evaluating design of electrodes
  • Inventing new applications
weldability lobe curves and weld nugget size development
  • Predicting weldability lobes and weld growth curves
  • Optimizing process parameter settings
  • Determining welding and cooling procedures
  • Trouble shooting welding problems

Welding simulation cases

SORPAS simulation of spot welding of 3 sheet

Spot welding:

Simulation of three-sheet spot welding of low carbon steel, high strength low alloy (HSLA) steel and Dual Phase (DP) steel sheets.

SORPAS simulation of 2d square nut welding

Projection welding:

Simulation of projection welding of square nut with corner projections welded to steel sheet showing the weld after collapse of the projections.

SORPAS simulation of resistance butt welding

Butt welding:

Simulation of resistance butt welding of two steel plates welded at the ends with resistance heating and subsequent forging and butt welding.

SORPAS simulation of parallel gap welding

Parallel gap welding:

Simulation of parallel gap welding (micro resistance welding) for joining thin foil to substrate plate of titanium alloys.

Report of simulation

weld planning example from SORPAS

After each simulation, SORPAS® will generate a Report of Simulation for documentation.

Left image is a typical report for a spot welding simulation. In the upper part, it shows the initial welding conditions including material combinations, geometry of electrodes and workpieces as well as the welding process parameter settings. In the lower part, it shows the main simulation results with a selected process parameter curve, the final temperature distribution with the weld nugget dimension in each workpiece.