As critically important as welding is to the wide applications in manufacturing, assembly and repair, there are also many welding problems that need to be solved along the welding lifecycle, as illustrated in the figure, from Designing, Optimizing, Planning, to Producing and Evaluating the welds.
It is, however, not easy to find the root causes of many welding problems, partly due to the complexity of the welding processes, and partly due to the extremely fast welding process and the difficulty to reveal inside the weld.
The practical way of solving welding problems is heavily relying on trial-and-error by running a lot of physical welding tests with real materials on the real welding machines by first making the weld designs, then producing and evaluating the welds, and finally approving or rejecting a weld design, or commissioning a welding production. This is time consuming and highly costly.
The new digital approach with welding simulations 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.