SORPAS® Reference book

SORPAS® Reference Book

  • All
  • Application
  • Coating
  • Common welding problems
  • Electrode
  • General topics
  • Material
  • Nugget size
  • Simulation tips
What are the requirements for my PC to run SORPAS®?
The recommended computer specifications of PC requirements are as follows: Type of computer:           Server computer / desktop / laptop Operation system:           Windows 7 / Windows 8 / Windows 8.1 / Windows 10 System architect              64-bit system Processor speed:              3 GHz or higher Number of cores:              4 cores or more especially for SORPAS 3D RAM:                                  8 … Continue reading
Validation of SORPAS® Simulations

Many factors influence the simulation results. In order to minimize the amount of work that users have to do to verify the highly dynamically coupled numerical models and their interactions with the input conditions, we have already made a lot of verifications and validations of all models with lab tests and user feedback. Many numerical … Continue reading

The critical role of hold time in weld quality and performance

Optimizing hold time shapes cooling rates, hardness distribution, and fracture behavior in resistance spot welds. This case study explores the effect of hold time on hardness and strength of weld nugget.

Optimizing hold time shapes cooling rates, hardness distribution, and fracture behavior in resistance spot welds. This case study explores the effect of hold time on hardness and strength of weld nugget.
SORPAS® material database – Add a new material
Folders in database When you create new materials, we recommend that you first create a folder in which you place your customized materials. This makes it easier to keep track of what is standard materials and what is your customized materials. See instruction on how to create materials below. Variations of standard materials You can … Continue reading
SORPAS® electrode database – Add a new electrode

If the electrode you want to use for the simulation is not in the library, you contact us on our support portal with specifications of the electrode from your supplier. If you are an active user of SORPAS®, we add the material free of charge. You can also add the electrode yourself, follow the instructions … Continue reading

SORPAS® – How to show nugget size between dissimilar materials
When welding dissimilar materials together, like aluminum and steel, normally, only the aluminum sheet melts and no melting of the steel sheet occurs. In this case, you can show the weld nugget size with two options. Go to “Preferences”, check the “Nugget Size at Interface” and set the slider at “Larger” This shows the final … Continue reading
Shunt effect in resistance spot welding

The shunt effect in resistance spot welding occurs when part of the welding current flows through previously made, closely spaced welds. This study investigates how the shunt effect behaves under different welding conditions.

The shunt effect in resistance spot welding occurs when part of the welding current flows through previously made, closely spaced welds. This study investigates how the shunt effect behaves under different welding conditions.
Selecting parameters that cover sheet gaps for stable production

Gap between welding parts can cause unstable welding production such as, early splash, no weld due to bad contact or improper gap closure. This case study shows how the gap size affects the splash limit and the lower limit of process window.

Gap between welding parts can cause unstable welding production such as, early splash, no weld due to bad contact or improper gap closure. This case study shows how the gap size affects the splash limit and the lower limit of process window.
Process window and strength of steels

The weldability of material is different from each other. It also means each material has its own process windows.

The weldability of material is different from each other. It also means each material has its own process windows.
How to improve accuracy in simulations?
In order to minimize errors in the simulation, we recommend that you check carefully the following points to see if they are correct before pressing "Start simulation": Geometric models and dimensions Sheet thickness Coating thickness Electrode shape / bulk diameter / tip diameter Electrode tip face curvature Material data Sheet material Coating material Electrode material … Continue reading
Guideline for Preparing a SORPAS® Simulation Task
Below are the guidelines for preparing the data for a simulation task: 1. Material properties data (for each material of workpiece, coating, electrode, rivet, die) Material name Material type or grade, tempering status, aging conditions etc. Chemical composition with percentage of each element Mechanical properties, incl. yield strength, tensile strength, elongation at break, n-value Physical … Continue reading
Export of data

Export of data to LS-Dyna You can export your simulation results from SORPAS® 3D into LS-Dyna. Go to: “File/Export/Results to LS-Dyna Export of data to DynaWeld You can export your results from SORPAS® 2D into DynaWeld. The interface enables you to export process simulation results from SORPAS® and continue the simulation with DynaWeld. Choose “File/Export … Continue reading

Evaluating electrode materials for reliable resistance brazing

This case study compares how different electrode materials influence heat generation, melting behavior, and energy use in resistance brazing. Four material combinations were tested to show how electrode temperature changes and effect on brazing materials.

This case study compares how different electrode materials influence heat generation, melting behavior, and energy use in resistance brazing. Four material combinations were tested to show how electrode temperature changes and effect on brazing materials.
Can I use an absolutely flat tip design for the electrode?
Absolute flat tip of electrode does not exist in reality. Even if they made the design with absolute flat tip, after just one weld, the tip face is deformed to have a natural curvature with a radius of R=50mm to R=100mm approximately. The ISO Standard electrode forms are mostly with tip face curvature R=50mm. If … Continue reading
Can I add coating to a rivet?

Yes, in SORPAS® 2D. joining you also have the possibility to add a coating to the rivet like in 2D. welding. On how to add coating to the rivet follow these steps Open the file and go through edit data file. Select the rivet you want to add coating on. Under Geometry and Materials find … Continue reading

Boosting production with energy efficiency in spot welding

Energy efficiency in resistance spot welding depends on choosing parameters that avoid unnecessary heat input. This case study uses four weld examples to show how total optimization reduces energy waste while preserving weld strength and process stability.

Energy efficiency in resistance spot welding depends on choosing parameters that avoid unnecessary heat input. This case study uses four weld examples to show how total optimization reduces energy waste while preserving weld strength and process stability.