SORPAS 2D v16.0

Released in August 2026

The fully upgraded SORPAS® 2D v16.0 is officially released. This new version introduces a wide range of new features, including the first generation of AI-enhanced models for digital optimizations of spot welding. By combining physics-based simulations with AI-based surrogate models, this version delivers practical and measurable benefits to welding production. This page summarizes the new features, improvements, and bug fixes included in this version.

weld quality radar chart

Quality Radar Chart and Score

Gain a complete view of weld quality through a 6-axis Radar Chart that simultaneously evaluates six critical quality indicators: Nugget Diameter, Nugget Penetration, Splash Severity, Surface Indentation, LME Cracking Risk, and HAZ Softening. Each criterion is scored from 0 to 100 and automatically aggregated into an overall Weld Quality Score, categorized into five standardized grades: Excellent, Good, Fair, Poor, and Defective.

AI-Enhanced Optimization & Weld Planning

Drastically reduces total computation time by incorporating AI-enhanced modes for Weld Lobes and Weld Growth Curves, cutting the required number of simulations for an entire 3D weld lobe to roughly 1/3 or half. This feature integrates advanced AI surrogate models trained on massive, multi-case welding datasets to rapidly execute Weld Planning and identify optimal parameters for a larger process window.

multiple weld lobes generated with three parameters, current, time, and force

3D Weldability Lobes with Splash Map

Easily configure and simulate 3D weld lobes by combining Force, Time, and Current to evaluate the complete welding process window. The resulting weldability lobe clearly identifies the optimal green safety zone and classifies process limits into four levels of splash severity. The Excessive Splash zone indicates the hard limits of operation and should be avoided when defining robust welding conditions.

weldability chart shows the overall weldability and sheet feasibility

Weldability Chart and Optimization

Quickly assess weld task feasibility using a General Weldability Score derived from 3D weld lobe simulations across the full parameter space. The score classifies weldability into five levels: Easy, Moderate, Challenging, Difficult, and Unfeasible. In addition, the new Weldability Chart highlights the best achievable weldability through digital optimization, including the largest process window and the resulting weld quality score.
  • High-Precision Dynamic Splash/Expulsion Factor – The updated splash model (no. 10) dynamically predicts splash timing, registers the initiating object ID, and synchronizes expulsion events with temperature animations and process curves. Dynamic splash factors, with a calibrated threshold around 1.0, are saved in the .CSV output.
  • Goal-oriented Automatic Model and Simulation Setup – A new workflow automatically configures the correct calculation models and required cooling times when users pre-select desired evaluation goals like Hardness or LME crack risk. This ensures model completeness and prevents incomplete results due to manual setup omissions.
  • Contact Resistance & Initial Thermal Calculation Refinements – Refinements in contact resistance formulations generally improve weld accuracy and eliminate artificial “ears” at nugget corners. Electrical calculations at the initial steps are also improved to prevent unrealistic temperature spikes.
  • Multi-format Media Export – Users can export on-screen graphics directly as PNG images or capture active animations as GIF and MP4 videos.
  • Phase Transformation-Based Residual Stress & LME Modeling – Residual stress calculation have been updated to account for the phase transformations of steels. These enhanced stress profiles are fed directly into LME models to produce realistic predictions of the intensity, distribution, and overall crack risk of Liquid Metal Embrittlement.
  • Electrode Indentation Calculation & Logging – A new physical calculation model dynamically computes electrode indentation on both upper and lower sheets. The calculated dynamic indentations are visually displayed on the final temperature view and automatically output to the .CSV result file.
  • Faster Lobe Simulation Launches – Launch speeds for batch simulation of Weld Lobes and Weld Growth Curves are significantly improved. By generating the mesh only for the first simulation and duplicating it across remaining cases with identical geometries, simulation overhead is minimized.
  • Electrode Block Auto-Merging & Hybrid Input Wizard Updates – The software automatically detects physically separate but connected blocks belonging to the same electrode and merges their mesh into a single object. Additionally, updates to the Input Wizard streamline the setup of complex models, including blank holders, dies, rivets, and electrodes for hybrid or mechanical joining.
  • Process Curve Filtering – Massive multi-weld datasets are now automatically filtered to display complete, clean parameter curves without graphical truncation.