Welding is widely applied in manufacturing industry for assembly and repair. Due to complexity of the weld designs and material combinations, there are many welding problems that need to be solved along the welding lifecycle from Designing, Optimizing, Planning, to Producing and Evaluating the welds, as illustrated in the figure.
Due to lack of effective methodology and tools to reveal inside the weld during the rapid and highly dynamic welding processes, it is quite difficult to find the root causes of many welding problems.
A practical but outdated way of solving welding problems is by trial-and-error with a lot of physical welding tests using real materials on the real welding machines. This requires to first get the real materials and produce the weld parts, then conduct a lot of welding tests and evaluate the welds, to finally approve or reject a weld design or optimize a welding production. This is time consuming and highly costly.
The new digital approach with welding simulations and optimizations can work concurrently crossing different phases of the welding lifecycle. For example, it is possible during Designing to evaluate the weld results by predicting the weld sizes and weld strengths, and also possible to optimize the welding process before launching a stable welding production.
On the following pages, we present in details the welding solutions by simulations with guidelines on how to make good weld designs, setup stable welding production and produce successful welds with support of simulations through every phase of the complete welding lifecycle:
We will then lead the way in digitalization of welding to present the new approach for creating the Welding Digital Twins with definition of each digital twin for every phase of the complete welding lifecycle.