Weld Distortion Control Methods and Applications of Weld Modeling

Computational weld modeling is challenging because many of the processes of welding are highly nonlinear. Material melts and re-solidifies, very high transient thermal gradients are experienced, non-linear temperature dependent plastic straining and phase transformations can occur, among other sources of nonlinearity. Moreover, for weld modeling to have practical advantages in industrial production, computational solution times must be manageable since an optimum weld design of large, complex fabrications requires numerous separate analyses. Weld modeling technology is now advanced to where it can have an important impact on numerous fabricated structures. These include nuclear power plant components in commercial nuclear plants and nuclear ship structures, including Aircraft Carriers, Submarines, and Destroyers. The benefits of weld modeling include: • Significantly reduced Fabrication Costs. • Life cycle cost reduction from improved corrosion, and fatigue performance and damage reduction enhancement. • Elimination of non-valued added re-work fabrication costs. • Improve readiness by speeding the time from conception to service for new designs. • Outreach program to continue paradigm shift improvements in welded fabrications. Weld distortion control must be performed on three dimensional models. Here, extensive full-scale experiments have validated the accuracy and predictive power of models. It can be used to reduce fabrication cost and improve quality by minimizing and controlling distortions. Several application examples are presented to illustrate how to apply this tool in welded structure design and manufacture.