Large-Scale Welding Process Simulation by GPU Parallelized Computing

Huang, Hui; Chen, Jian; Feng, Zhili; Wang, Huiping; Cai, Wayne; Carlson, Blair E.

doi:10.29391/2022.101.032

Title: Large-Scale Welding Process Simulation by GPU Parallelized Computing

Full Record
Other Related Research

Abstract

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes formore » large-scale structures.« less

Authors:

^[1];

^[1]; Wang, Huiping ^[2]; Cai, Wayne ^[2]; Carlson, Blair E. ^[2]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
General Motors Company LLC, Warren, MI (United States)

Publication Date:: Mon Nov 01 00:00:00 EDT 2021

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:: 1855696

Grant/Contract Number:: AC05-00OR22725

Resource Type:: Accepted Manuscript

Journal Name:: Welding Journal

Additional Journal Information:: Journal Volume: 100; Journal Issue: 11; Journal ID: ISSN 0043-2296

Publisher:: American Welding Society

Country of Publication:: United States

Language:: English

Subject:: 97 MATHEMATICS AND COMPUTING; Welding Simulation; Finite Element Method (FEM); Welding Distortion; Residual Stresses; Graphics Processing Unit (GPU) Parallel Computing; Laser Brazing

Citation Formats


                    Huang, Hui, Chen, Jian, Feng, Zhili, Wang, Huiping, Cai, Wayne, and Carlson, Blair E. Large-Scale Welding Process Simulation by GPU Parallelized Computing.  United States: N. p., 2021. 
Web.  doi:10.29391/2022.101.032.

Copy to clipboard


                    Huang, Hui, Chen, Jian, Feng, Zhili, Wang, Huiping, Cai, Wayne, & Carlson, Blair E. Large-Scale Welding Process Simulation by GPU Parallelized Computing.  United States.  https://doi.org/10.29391/2022.101.032

Copy to clipboard


                    Huang, Hui, Chen, Jian, Feng, Zhili, Wang, Huiping, Cai, Wayne, and Carlson, Blair E. Mon .  
"Large-Scale Welding Process Simulation by GPU Parallelized Computing".  United States.  https://doi.org/10.29391/2022.101.032.  https://www.osti.gov/servlets/purl/1855696.

Copy to clipboard


                    
@article{osti_1855696,

  title        = {Large-Scale Welding Process Simulation by GPU Parallelized Computing},

  author       = {Huang, Hui and Chen, Jian and Feng, Zhili and Wang, Huiping and Cai, Wayne and Carlson, Blair E.},

  abstractNote = {The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.},

  doi          = {10.29391/2022.101.032},

  journal      = {Welding Journal},

  number       = 11,

  volume       = 100,

  place        = {United States},

  year         = {Mon Nov 01 00:00:00 EDT 2021},

  month        = {Mon Nov 01 00:00:00 EDT 2021}

}

Copy to clipboard

Journal Article:

Free Publicly Available Full Text

Accepted Manuscript (DOE)

Publisher's Version of Record

https://doi.org/10.29391/2022.101.032

Other availability

Search WorldCat to find libraries that may hold this journal

Save / Share:

Export Metadata

Save to My Library

Similar Records in DOE PAGES and OSTI.GOV collections:

Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach

Conference Huang, Hui ; Chen, Jian ; Feng, Zhili ; ...

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three-dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems thatmore »« less
https://doi.org/10.1115/PVP2018-85044

Full Text Available
Development of a Comprehensive Weld Process Model

Technical Report Radhakrishnan, B ; Zacharia, T

This cooperative research and development agreement (CRADA) between Concurrent Technologies Corporation (CTC) and Lockheed Martin Energy Systems (LMES) combines CTC's expertise in the welding area and that of LMES to develop computer models and simulation software for welding processes. This development is of significant impact to the industry, including materials producers and fabricators. The main thrust of the research effort was to develop a comprehensive welding simulation methodology. A substantial amount of work has been done by several researchers to numerically model several welding processes. The primary drawback of most of the existing models is the lack of sound linkagesmore »« less
https://doi.org/10.2172/2737

Full Text Available
Development of a comprehensive weld process model

Technical Report Radhakrishnan, B ; Zacharia, T ; Paul, A

This cooperative research and development agreement (CRADA) between Concurrent Technologies Corporation (CTC) and Lockheed Martin Energy Systems (LMES) combines CTC`s expertise in the welding area and that of LMES to develop computer models and simulation software for welding processes. This development is of significant impact to the industry, including materials producers and fabricators. The main thrust of the research effort was to develop a comprehensive welding simulation methodology. A substantial amount of work has been done by several researchers to numerically model several welding processes. The primary drawback of most of the existing models is the lack of sound linkagesmore »« less
https://doi.org/10.2172/505741

Full Text Available
CRADA Final Report: Weld Predictor App

Technical Report Billings, Jay Jay

Welding is an important manufacturing process used in a broad range of industries and market sectors, including automotive, aerospace, heavy manufacturing, medical, and defense. During welded fabrication, high localized heat input and subsequent rapid cooling result in the creation of residual stresses and distortion. These residual stresses can significantly affect the fatigue resistance, cracking behavior, and load-carrying capacity of welded structures during service. Further, additional fitting and tacking time is often required to fit distorted subassemblies together, resulting in non-value added cost. Using trial-and-error methods to determine which welding parameters, welding sequences, and fixture designs will most effectively reduce distortionmore »« less
https://doi.org/10.2172/1432162

Full Text Available
Thermomechanical Analysis of A-TIG and MP-TIG Welding of 2.25Cr-1Mo Steel Considering Phase Transformation

Journal Article Pavan, A. R. ; Arivazhagan, B. ; Zubairuddin, M. ; ... - Journal of Materials Engineering and Performance

In the present study, a finite element-based 3D mesh model is used to simulate the effect of welding processes on the temperature distribution, residual stress and distortion in 11-mm-thick 2.25Cr-1Mo steel weld joints. Tungsten inert gas (TIG) and activated-TIG (A-TIG) welding processes were employed for the fabrication of weld joints. Austenite-to-bainite phase transformation is taken into account in the numerical analysis. The heat input fitting tool has been used to calibrate the heat source by matching the simulated weld bead with that of the actual weld bead. Peak temperature was higher at the weld center for A-TIG weld joint, andmore »« less
https://doi.org/10.1007/S11665-019-04243-4

Similar Records