Residual Stress, Distortion Prediction, Sequence Optimization in Welding Process

We are an  interdisciplinary group of specialists in Process Modeling, Simulation and Advanced Finite Element Analysis.

We have an high level experience in Modeling of Welding Process to predict

  • Residual Stress
  • Distortion
  • Heat Affected Zone (HAZ)
  • Fatigue, Fracture and durability of the welded structures
  • Welding Sequence Optimization

TIG/ MIG/ LASER/ELECTRIC ARC/ ELECTRON BEAM/ELECTRICAL SPOT RESISTANCE welding (single/ multi pass) are simulated using FEM tools.

Residual Distortions

Residual distortion prediction in the welding process considering the effect of process parameters – like HAZ, weld sequence, thermo-mechanical properties on distortion level. Computational modeling of welding process and prediction of distortion level in welding of similar and dissimilar materials, fusion and solid state welding process. Optimization studies of on the minimization of distortion level.

Residual Stresses

We experience in predicting the level of residual stresses and helps to calculate the in-service fatigue life of the manufactured part. We perform Non-linear modeling of Thermo-Mechanical- Metallurgical process is accounting the thermal and metallurgical changes and the mechanical stress developed and  followed to predict the residual stress induced during the process.

Metallurgy and Quality

Welding material and metallurgy studies helps in understanding the material behavior and metallurgical changes during the welding process and weld-zone solidification. Studies associated with Liquation cracking, Loss of strength and ductility,  Hydrogen-induced cracking, Weld zone shrinkage, hardness, HAZ zone length, strength studies and computational modeling of the same.

Welding Research and Optimization

Interdisciplinary Research on Welding Process, Material, Metallurgy and Life Assessment. DHIO brings an team with decades of experience in welding research & development. We experience in welding process correlation with testing and simulation data and calibration of finite element models for

• Weld sequence optimization
• Complete understanding of the welded component during welding, cooling and in service

DHIO has worked on fatigue, crash, and impact resistance analysis and micro-structural analysis of welding; development of alternate welding processes, (friction /friction stir/ tubular welding/ deformation resistance welding; and optimization of weld sequence to minimize the weld distortion.

Frequently Asked Questions

Still open questions?

Yes, it is possible to predict the distortion level in welding process. we need to perform nonlinear FEM taking in to account mechanical, metallurgical and thermal changes.

Yes, It is possible to develop the welding process for any specific material, our services includes practical welding process testing for a given material and welding simulation based correlation.

Yes, it is possible to develop the Artificial Neural Network based optimized weld zone or HAZ based on the change in IV Characteristics of the welding process.

Yes, it is possible to consider the residual stress induced during the weld life estimation.