Virtual welding ready to replace experimentation

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Virtual welding ready to replace experimentation !
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FIAT invests in virtual prototypingto avoid
costly design errors

• CRFiatwe are doing some enquiries to fill the
  figure I need still some days to find data

Release
10000x
Testing
Development phase
1000x
Tooling
100x
Cost to implement change
Design
10x
Concept
x
welding simulation application phases
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Welding simulation benefits

• Distortions minimised no costly adjustments
• Residual stresses minimised improved quality
  lifetime
• Better knowledge of welding process
  optimisation of production

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What about you ?

• Are you sure your welding processes are optimised
  ?
• How much money do you lose in off-spec products ?

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Numerical simulation Parallel computingis
your business solution
SYSWELD
HPCN
Developed by PHPC METAL (EC funded)
State-of-the-art technology
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SYSWELD leading software forwelding heat
treatments simulation

• Takes into account metallurgical phenomena and
  their effects on the mechanical behaviour of
  structures
• volume changes due to phase transformations
• change in mechanical properties due to phase
  transformations
• transformation plasticity

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SYSWELD leading software forwelding heat
treatments simulation

• Dedicated tools to welding simulation
• pre-defined mobile heat sources
• material deposit
• steady state computation in a
• moving reference frame

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SYSWELD all industrial welding processes
spot welding
GTA welding
Laser welding
Electron beam welding
MIG welding
Multipass submerged arc welding
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SYSWELD reliable results
Multipass submerged arc welding
Comparison of transverse residual stresses
between simulation and X-Ray diffraction
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HPCN benefits

• distribute memory on several machines big
  models can be calculated

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HPCN benefits (2)

• parallel computing performances gains
• calculation time compatible with industrial time
  constraints

Speedup
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Example FIAT business case
Real part

• Problem Overlap arc welding of a rear axle
  system
• Objectives Optimisation of the joint
  microstructural conditions after welding

pipe
FEM Model
support
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FIAT business case Thermo-metallurgical
analysis

• CRFiat to start animation it is sufficient to
  click on the picture to call the program and to
  click again to run it

Evolution of temperature field during welding
process
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FIAT business case thermo-metallurgical
analysis

• CRFiatThis is to show how computation fits well
  reality. The support (at the beginning 100
  bainitic) slightly changes its structure at the
  interface with beam, the pipe (at the beginning
  100 ferritic) heavily changes at the interface
  and becomes 80bainitic20martensitic. Real beam
  material is different from the other two steel
  in the simulation it is the same as the pipe and
  so shows the same microstructure of the pipe.

(x100)
Beam-support interface
Beam-pipe interface
Ferrite
Bainite
Martensite
Comparison between experimental and computed
final metallurgical status
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FIAT business case mechanical analysis

• CRFiat the two main effects on shape are
  enlightened structure lengthening and distortion
  of support near welded beam

Amplification factor 50
Comparison between initial joint shape and
distorted geometry after welding
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Benefits...

• Design time for the part divided by two
• Optimisation Best possible quality achieved
• Purchase the right manufacturing tools at the
  first time

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Example Visual Analysis business case

• Problem Welding of a motorcycle wheel made of
  aluminium
• Objectives Optimisation of welding process
• minimise loss of hardness
• distortions after unclamping
• within tolerance

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Visual Analysis business case thermo-metallurgic
al analysis
Running heat source
Molten zone
Temperature field after 58 s
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Visual Analysis business case mechanical
analysis
Loss of hardness
Distortions after unclamping
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Benefits the golden triangle
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A technology accessible to SMEs

• Services providers propose on-demand studies at
  attractive price
• Target platform for future versions Windows NT
• Big interests at stake SMEs customers may
  participate to the investment

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Virtual welding can bring you competitive
advantages

• contacts

IRSID Philippe Autesserre philippe.autesserre _at_irs
id.usinor.com