Ardalan Amiri in Mechanical Engineering, Engineers and Technicians, Mechanical and Welding Design Analysis Engineer • L.T.Calcoli Dec 25, 2019 · 1 min read · 8.6K

Welding Process Simulation via FEA to Better Predict the Aftermaths

Welding simulation and providing prognostic predictions for welding engineers are not amateur works. Do not let market minded software sellers mislead you on the matter. From complex process of thermostructural stress relaxation rates in face of phase change and annealing to material deposition and HAZ cooling methods, a standard welding process simulation is a high fidelity job demanding accurate viscoelstoplastic data and only trusted in the hands of professionals. A job that is the basis for residual stress calculation and creep estimation.

Me and my colleagues at L.T. CALCOLI S.R.L. have done academic research, wrote books and have performed critical industrial projects on the matter for nuclear facilities and laser welding applications.

Welding Process Simulation via FEA to Better Predict the Aftermaths

Someday you welded that pipe connection within some pipe line somewhere and you think you are done, after a year or so the whole pipeline explodes so badly that you gonna have a hard time !

Preventing such catastrophic failures, mechanical/metallurgical researchers asked to extend the science of welding to the so called "long term welding effects".

What happens after you weld your pipe? 

Well, to be honest it is not so straightforward (otherwise those kind of researchers had many other sophisticated stuffs to do!) . Yet many, including power plant and nuclear industries, are not only regarding this question but also do their best and spend money to prevent undesired welding consequences. Since those consequences are so damaging and risky specially in the critical working conditions, one accepts to spend some money to avoid huge money, reputation and in some cases certificate loss. Pipe lines life time and reliability have been subjects of intensive studies for many years and still welding engineers in extreme working pipelines, like those of nuclear facilities, need to predict the damages and forecast the safe zone working time span of their welded joints.

Looking at the papers and articles published within the last 10 years concerning the mentioned matter, it is quite clear that researchers are funded and requested by big time industries and companies to perform the investigations so that a welding engineer considers the resultant criteria, advice and conclusions in order to fix a proper set of regulations, instructions and guidelines for welder labors in pipelines.

Now if you still wonder "what happens after welding a pipe?" and you like to know then you have got two ways to do so:

1. Study the triple reaction network of thermal-metallurgical-mechanical fields within a weld bead and the corresponding HAZ zone as welding and some years after welding. (which essentially needs you to be either a nerd or a crazy student of mechanical engineering named Ardalan Amiri itching for challenge !)


2. Follow my posts and/or ask me to introduce you to a simple and illustrating book of mine (which I am so proud of it that I gonna put the link below even before you ask for it !)

My beloved book :)

Either you are a power plant risk analyst or just an enthusiast amateur in the wide field of welding engineering, you can learn a lot from that book and my knowledge of computational simulation power against disasters.