Welding Problems and Solutions

Many have encountered complex welding problems that are difficult to solve because it is hard to find the root causes. You may wonder,

  • Is the problem caused by a bad design of the weld?
  • Is the problem caused by an improper combination of materials?
  • Is it caused by poor process settings that are not well-optimized?
  • Is it caused by the wrong type of electrodes, or anything else?

Due to the lack of effective tools to reveal the inside of the weld zone during the rapid and highly dynamic welding process, a practical but tedious way to detect the welding problems is by trial-and-error with a lot of physical weld tests using real materials on a real welding machine.

> The trial-and-error approach is time-consuming and highly costly.

The new approach with simulations and optimizations can work concurrently crossing different stages of the welding lifecycle from designing, optimizing and planning, to producing and evaluating the welds.

For example, it is possible to reveal inside of the welds and evaluate the welding results by simulations to predict the weld nugget sizes and weld strengths during Designing phase. It is also possible to optimize the welding process settings before launching the welding production.

> The new approach with simulations is easy, fast, and cost-effective!

On the following pages, we will present in detail the welding solutions by simulations and optimizations with guidelines on how to make good weld designs, achieve stable welding productions, and produce high-quality welds with support of simulations and optimizations 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.

Resistance welding problems

Weld splash

Weld splash (expulsion/spatter) happens when molten material comes out from the weld nugget. It causes cosmetic problems, defective welds, safety ...
spot welding of two steels sheets with Zinc coating shows high risk of crack at the lower sheet.

Liquid metal embrittlement

Liquid metal embrittlement(LME) is a phenomenon where certain metals like Al and steels undergo brittle failure when stressed in contact ...
comparison of used and new electrode. The used electrode has increased tip diameter.

Electrode degradation

Electrode degradation is one of the common problems in the welding industry. It decreases the nugget size due to reduced ...

Welding case studies with SORPAS®