Welding simulation for temperature stress, distortion and cracking

Welding simulation for temperature stress, distortion and cracking

Welding simulation for temperature loading, distortion and cracking

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Prediction of the effect of welding on the structure

With our welding structure simulation, you will be able to see an individual welding processes (weld, spot) and the behavior of the welded assembly during welding. The simulation model can represent conventional welding processes (resistance spot welding, laser welding, arc welding, etc.) as well as additive manufacturing (e.g. AM-DED).

Significant reduction in workload and development times
© Fraunhofer IPK
Significant reduction in workload and development times when introducing new welded assemblies through simulation
Warpage optimization of a vehicle door
© Fraunhofer IPK
Warpage optimization of a vehicle door: variant testing with simulation and optimization of the welding sequence by calculating the warpage potential of individual welds. Cost savings: 20 % - 60 % (personnel, material, reworking).
Thermal simulation for e-mobility
© Fraunhofer IPK
Thermal simulation for e-mobility: For this battery cell contacting, the simulation ensured that certain temperatures are not exceeded at a critical point during welding. Savings potential of up to 40 % with advanced design.

Our service for you: Combination of Fraunhofer IPK: research and simulation software for model creation and evaluation.


Our offer for you: Structural simulation for all common welding processes

  • Analyze: Identification of factor "invisible" in the experiment but relevant for the welding result
  • Evaluate: Assessment of simulation results and derivation of optimization strategies for distortion
  • Optimize: Susceptible structures are improved to cracking


What to expect?

  • Calculation of temperature load, residual stress and welding distortion
  • Design of process windows and clamping tools
  • Virtual validation for drastic reduction of testing effort

For a successful simulation you should provide some of your process data.

Minimum requirements

  • Component or welded structure (CAD, sketch)
  • Welding process (procedure, filler materials, ...) with parameters (first empirical values)

Ideal requirements

  • Material data or test materials
  • Transverse sections of the weld

Your benefits and advantages: By using our simulation methods, time-consuming and costly experiments can be drastically reduced.

  • Cost savings: Fewer welding tests necessary - Determination of weldability, welding distortion and parameter window on the computer
  • Time savings: Virtual optimization can be realized faster than experimental tests (especially for large components)
  • Savings in experimental effort (up to 70 %) and prototype tools (up to 80 %)
  • Virtual validation before the first experiments: Digital mapping of the welding process enables optimizations in terms of material, welding sequence and design
  • Improvement of process understanding, such as residual stress, temperature, critical seams that increase distortion, etc.

The solution is interesting for these industries:

  • Steel construction/shipbuilding
  • Automotive/rail vehicle construction
  • Aerospace

Weld structure simulation

Get in touch!

We would be happy to talk individually about your challenge and present our solution approaches. Let us advise you without obligation and learn more about our solution.