Optimization of Welding Processes : Innovative Joining Processes Applying Integrated Modelling

  • Bendsøe, Martin P. (Project Participant)
  • Bogomolny, Michael (Project Participant)
  • Larsen, Anders Astrup (Project Participant)

    Project Details


    Advanced industrial product development is faced with steadily growing demands for joining new materials, often
    in dissimilar combinations, implying complicated joining problems. It is therefore imperative that manufacturing
    of joints in high tech products should be treated with scientific engineering methods. This is, however, seldom
    done to an extent justified by its importance.
    Although traditional arc welding processes have been subjected to numerical analysis of isolated problems such
    as temperature analysis, weld pool dynamics, microstructural evolution as well as transient and residual
    stress/strain and distortion analysis the idea of modeling with the aim of optimizing the entire process is still in its
    infancy state, and when it comes to more sophisticated processes like resistance welding (RW) and friction stir
    welding (FSW) even more basic numerical studies are in an early stage of development. Both of these
    processes need complex thermo-mechanical calculations, microstructural predictions as well as thorough
    analysis of large plastic deformations in order to predict weld strength and optimum welding parameters as well
    as final geometry.
    These problems are challenging and of multi-physics nature involving complex mechanisms comprising several
    cross-disciplinary areas such as materials science, thermodynamics, solid and fluid mechanics as well as
    process technology and applied numerical analysis.
    The objective of the present project is to develop advanced numerical models applicable for simulation of RW
    and FSW aiming at possible optimization of the entire processes. Focus will be set on overall numerical
    modelling strategies specific for each of the two welding processes as well as more detailed investigations of
    microstructures, mechanical properties, strength and weld quality. The part of the project carried out at MAT is concernced with optimization of the welding processes using rational computational tools from optimal design and sensitivity analysis.
    Effective start/end date01/01/200631/12/2009


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