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.
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.
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.
- Evaluating weldability of materials
- Evaluating design of weld combinations
- Evaluating design of electrodes
- Inventing new applications
- Predicting weldability lobes and weld growth curves
- Optimizing process parameter settings
- Determining welding and cooling procedures
- Trouble shooting welding problems
Welding simulation cases
Simulation of three-sheet spot welding of low carbon steel, high strength low alloy (HSLA) steel and Dual Phase (DP) steel sheets.
Simulation of projection welding of square nut with corner projections welded to steel sheet showing the weld after collapse of the projections.
Simulation of resistance butt welding of two steel plates welded at the ends with resistance heating and subsequent forging and butt 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
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.