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Computational welding mechanics

L-E Lindgren, Luleå University of Technology, Sweden

Woodhead Publishing Series in Welding and Other Joining Technologies No. 60

Some of the numerical methods described in the book are illustrated using software available from the author which allows readers to explore CWM in more depth.
Welding and Cutting

 - highlights the principles, methods and applications of CWM
 - discusses the physics of welding
 - assesses modelling methods and validation techniques
 - reviews applications in areas such as fatigue, buckling and deformation, and process optimisation

Computational welding mechanics (CWM) provides an important technique for modelling welding processes. Welding simulations are a key tool in improving the design and control of welding processes and the performance of welded components or structures. CWM can be used to model phenomena such as heat generation, thermal stresses and large plastic deformations of components or structures. It also has a wider application in modelling thermomechanical and microstructural phenomena in metals. This important book reviews the principles, methods and applications of CWM.

The book begins by discussing the physics of welding before going on to review modelling methods and options as well as validation techniques. It also reviews applications in areas such as fatigue, buckling and deformation, improved service life of components and process optimisation. Some of the numerical methods described in the book are illustrated using software available from the author which allows readers to explore CWM in more depth.

Computational welding mechanics is a standard work for welding engineers and all those researching welding processes and wider thermomechanical and microstructural phenomena in metals.

ISBN 1 84569 221 7
ISBN-13: 978 1 84569 221 6
July 2007
248 pages  234 x 156mm  hardback  
£130.00 / US$220.00 / €155.00

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About the author

Lars-Erik Lindgren is Professor of Material Mechanics at Luleå University of Technology, Sweden. He has an international reputation for his research in such areas as computational welding mechanics.

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Welding processes handbook

Contents

Introduction
 - Computational welding mechanics
 - Contents of book
 - The competent company
 - Driving forces for increased use of welding simulations

The multi-physics of welding

Couplings and reference frames
 - Coupled systems and solution procedures
 - Linearised coupled thermo-elasticity
 - Decoupling of the sub-domains of welding simulations

Thermo-mechanics of welding
 - The thermal cycle and microstructure evolution
 - The Satoh test
 - Welding of plate
 - Welding of pipe

Nonlinear heat flow
 - Basic equations of nonlinear heat conduction
 - Finite element formulation of nonlinear heat conduction

Nonlinear deformation
 - Basic choices in formulation of nonlinear deformation
 - Finite element formulation of nonlinear deformation
 - Constitutive model
 - Stress updating algorithm for deviatoric plasticity

Numerical methods and modelling for efficient simulations
 - Element technologies
 - Meshing
 - Dynamic and adaptive meshing
 - Substructuring
 - Parallel computing
 - Dimensional reduction
 - Weld pass reduction
 - Replacement of weld by simplified loads

Calibration and validation strategy
 - Definitions of concepts used
 - Code verification
 - Model refinement and qualification
 - General approach for validation
 - Calibration and validation strategy
 - Validation using subsystems and complete systems

Modelling options in computational welding mechanics (CWM)
 - A note about computability in CWM
 - The importance of material modelling
 - Effect of temperature and microstructure
 - Density
 - Thermal properties
 - Elastic properties
 - Plastic properties and models
 - Thermomechanical properties
 - Microstructure evolution
 - Material modelling in weld pool
 - Surface properties
 - Heat input models
 - Geometric models

Modelling strategy
 - Accuracy and weld flexibility categories for CWM models
 - Characteristics of different accuracy categories
 - Motivation for proposed modelling strategy

Robustness and stability
 - Definitions concerned with robustness and stability
 - Perturbation methods for investigation of robustness
 - Methods for analysis of stability
 - Application of robustness and stability analysis in CWM

The current state of computational welding mechanics (CWM)
 - Heat input models
 - Material models
 - Models for fatigue and cracking
 - Computational efficiency
 - Simplified method
 - Reducing risk for buckling, deformations or residual stresses
 - Improved life
 - Repair welding
 - Optimisation
 - Simulation of welding and other manufacturing steps

The Volvo Aero story in computational welding mechanics (CWM)
H Runnemalm and H Alberg, Volvo Aero Corporation, Sweden
 - History
 - Strategic decisions for successful implementation
 - Business motivation for CWM
 - Examples

Summary and conclusion

References