ProgramMaster Logo
Conference Tools for 2023 AWS Professional Program
Register as a New User
Submit An Abstract
Propose A Symposium
Presenter/Author Tools
Organizer/Editor Tools
About this Abstract
Meeting 2023 AWS Professional Program
Symposium 2023 AWS Professional Program
Presentation Title Development of a Fast Analysis Solver for Welding Sequence Optimization of Ship Structures
Author(s) Yu-Ping Yang, Steve Scholler, Zhili Feng, Jian Chen, Hui Huang, John Walks
On-Site Speaker (Planned) Yu-Ping Yang
Abstract Scope During the shipbuilding manufacturing process, materials are exposed to significant stresses as induced both thermally and mechanically, that alter the intended design and significantly affect the production schedule, labor hours (fitting, welding, rework, etc.), and material structural performance. The type and magnitude of deformation of a given structure depends on many factors such as the material, thickness and quality of components, the process heat input, preheat and inter-pass temperatures, type and size of welds, welding sequence and direction, location, sequence, and degree of fixturing. Numerical simulations using Finite Element Analysis (FEA) have long been used to analyze and estimate welding distortion. Joint level detailed welding analyses are required to capture the physics driving distortion, and they are performed by expert analysts with insight to pedigreed material properties. For large assemblies, however, these analyses can take days or weeks to set up, run, and obtain results, and optimization is not feasible. Traditional approaches for performing welding analysis using FEA are not suitable for very large structures and production environments where hundreds of analyses are needed for each ship. A project team selected for funding by the National Shipbuilding Research Program (NSRP) proposes the development of a fully customizable fast analysis solver that can be used by shipyard Production Planning and Engineering groups for rapidly predicting weld-induced deformation of very large assemblies/sub-assemblies and optimizing their welding sequences to minimize the efforts. Oak Ridge National Laboratory (ORNL) has recently developed a superfast, high-performance computational (HPC) solver for weld residual stress and distortion simulations of large and complex welded structures. The solver takes full advantages of modern GPU-based HPC hardware and incorporates patented acceleration schemes based on many years of experience in welding simulation at ORNL. The speed gains depend on the size and complexity of the model - the larger the model, the greater the speedup. The speedup factors are in the range of 100 times for simple 3D models to 2200 times for large, multiple pass welded structures. This solver, recognized by the International Institute of Welding in 2021, has been successfully used in predicting distortion on automotive structures and nuclear piping systems. The project participants will develop a user-friendly and fast FEA solver for shipbuilding applications by leveraging ORNL’s and Hexagon’s prior work for the automotive and nuclear industries. This solver will enable quick computation of complex material modeling that can address ongoing design and manufacturing issues in the industry. The primary use-case for the development of this solver will be weld-sequencing simulation of panel and unit assembly construction. The complex nature of weld sequencing for distortion control will allow the team to understand the current solver time and computational requirements, address existing limitations, train engineers on efficient and accurate use of the tool, and utilize Hexagon’s robust graphical user interface to tackle the optimization of other manufacturing processes in shipbuilding and other industries. The team envisions a solver capable of replacing current analytical tools utilized to simulate welding processes that predict welding-induced stress distributions, and it can be used to improve ship structural designs, predict fatigue life and cracking in high stress areas, and minimize movement of alignment critical structures where hot work is required in the surrounding areas. Other potential applications include the optimization of the thermal straightening process used to correct distortion, prediction of heating paths for thermally forming curved shell plates, optimization of the hybrid laser arc welding process to improve toughness, and dynamic simulation of mechanical systems.
Proceedings Inclusion? Undecided


A Brief History of Welding Metallurgy in IIW
A Fundamental Investigation into Intermetallic Formation and Growth in the Aluminum-Iron System using Resistance-based Diffusion Couples
A New CALPHAD-based Finite Element Tool for Additive Manufacturing Simulation
Accelerating Ni-Cr Filler Metal Design with a Coupled CALPHAD and Data Analytics Approach
Additive Manufacturing and Welding of Ni-base Superalloys for Concentrated Solar Power Systems
Additive Manufacturing of Steel-aluminum Bimetallic Structures
Alloy Design and Additive Manufacturing of Functionally Graded Materials for Olefin Furnaces
Alloy Development via Multi-wire Arc Additive Manufacturing (m-WAAM)
Application of NDE Techniques for Safer Pressure Vessels
Applications of Emerging Artificial Intelligence Tools in Additive Manufacturing
Arc and Droplet Transfer Behavior During Electrode-negative Polarity Cold Metal Transfer and Electrode-positive Pulse Gas Metal Arc Deposition of Ti-6Al-4V Alloy
Arc Length Behaviour and Voltage Predictions for GMAW-Sp Aluminum Procedures in the Lincoln Procedure- Handbook
Automated Vision-based Laser Weld and Braze Quality Systems
Bond Formation Mechanism of High-frequency Electric Resistance Welding Of X65 Grade Pipeline Steel by Physical Simulation
Capacitor Discharge Based Resistance Welding of Aluminum Alloy and Galvanized Steel Sheets
Carbide Precipitation during Temper Bead Welding in the HAZ of Low Alloy Steels
Challenges in Additive Manufacture of Nickel Aluminum Bronze Alloys
Characterization of Vibration Welded Wood
Charpy Reconstitution Joining Procedure: Supporting Reactor Pressure Vessel Operation Beyond 60 Years
Comparison of Constant Load and Slow Strain Rate Tensile Tests for Evaluation of Hydrogen Assisted Cracking Susceptibility in Dissimilar Metal Weld
Comparison of Crystallographic Texture Before and After Post-weld Heat Treatment of Electric Resistance Welded X65 Linepipe
Computational Design of Experiment Process-microstructure-property Optimization in Welding and Additive Manufacturing
Computational Process-Microstructure-Property Optimization for Fe-10Ni Groove Welds
Connecting X-ray Computed Tomography to Fatigue Life of Ti-6Al-4V using Quantitative Fractography
Construction of a Unified Fatigue S-N Curve Incorporating the Effects of Residual Stress Level in Welded Joints
Correlation Between the Coarse and Fine Grain Haz Hardness of Pipeline Girth Welds
Creep Performance of Austenitic Stainless Steels Processed with Wire Arc Directed Energy Deposition
Critical Evaluation of NDE Methods and Their Effectiveness for Defect Detection in Laser Powder Bed Fusion Components
Crystallographic Texture and Microstructure of Dissimilar Steel Welds for Filler Metal Selection
Database of Hydrogen Assisted Cracking Susceptibility in Dissimilar Metal Welds
Deep Learning Based Real-time and In-situ Monitoring of Weld Penetration: Where We are and What are Needed Revolutionary Solutions?
Defect Formation Mitigation during Laser Welding of Aluminum Alloys using Beam Oscillation
Deleterious Effects of Laser Welding Nitinol without Argon Shielding Gas
Development of a Fast Analysis Solver for Welding Sequence Optimization of Ship Structures
Development of a New Technique to Assess Spot Welding Cracking of Gen3 High Strength Steel Sheets
Dissimilar Brazing of Ti-6Al-4V to Stainless Steel Under Thermal Conditions used for Glass Sealing
Do We Need a New Foundation to Use Deep Learning to Monitor Weld Penetration?
Droplet Temperature Measurements in GMAW
Effect of Additive Manufacturing Process Parameters on the Microstructure and Mechanical Properties of AF9628 Steel
Effect of Base Metal Dilution on Microstructure and Thermal Stability in Anviloy Wire-H13 Clads
Effect of Martensite-Austenite Morphology on Charpy Toughness of Cold-wire Tandem Submerged-arc Welded X70 Steel
Effect of Preheating Temperatures on Microstructure of L-DED Grade 91
Effect of Retained δ-ferrite on the Nucleation of Laves Phase during Artificial Aging in Grade P92 Steel Welds
Effect of the Notching Method on Charpy V-notch Impact Energy Outcomes
Effect of Wire Preheat and Feed Rate in X80 Steel Laser Welds
Effects of Deposition Sequence on Microstructural Evolution in Additively Manufactured Cu-Cr-Nb Alloy / Superalloy Bimetallic Structures
Energy Distribution and Effects on Weld and Defect Formation during Beam Oscillation Laser Welding of a Nickel Alloy
Erection Stage Longi Welding Robot System in Shipbuilding
Evaluation of Inoculated High Strength Aluminum Wire 6061 for GMA DED
Feasibility of LP-DED and L-PBF Processes in the Repair of GTD 111 Turbine Blades using René 65 Powder
Fluidity of Aluminum Welding Wires
Friction Stir Welding of Rolled Homogenous Armor (RHA) and High Hardness Armor (HHA) Steels
From Frustrating to Flawless: Mastering Class A Aluminum Resistance Welding
General Linear Models in Additive Manufacturing: Interpretability and Prediction of Aggregated Ti-6Al-4V Fatigue Data
General Thermomechanical Model of FSW Based on a Characteristic Temperature for Deformation and Heat Transfer
Geometrical Feature Development for Multi-Process DED of Aerospace Structures using Ultra High Strength Steel (UHSS)
High Ductility Brazes of Nickel-superalloys Using a Multi Principal Element Alloy Filler
Hot Wire Semi-auto Gas Tungsten Arc Welding (GTAW) for Shipbuilding Applications
Identifying Deposit Profile for Gas Metal Arc Directed Energy Deposition
Industrialization Challenges in Welding and Large Scale Metal Fabrication
Influence of Alloy Composition and Nitride Formation on Delta Phase Precipitation in Additively Manufactured Inconel® 625
Influence of Hydrogen Shielding Gas Additions on Base Metal Dilution, Bead Shape and Wall Buildability in Fe-10Ni Gas Metal Arc DED
Influence of Welding Parameters on Weld Reinforcement in Tandem Submerged Arc Welding
Inoculated High Strength High Strength Aluminum Wire Feedstocks for Welding and DED
Integrating a Novel Approach to Advanced Materials during Resistance Spot Welding for the Automotive Industry
Investigation of Defects Process Map in Friction Stir Welding
Investigation of Fe-10 wt.% Ni Steel Weld Metal Hydrogen Induced Cracking Susceptibility using the Gapped Bead on Plate (GBOP) Test
Investigation of Intermetallic Phase Formation during RSW of Advanced Automotive Steels and Aluminum Alloys
Isothermal Low Cycle Fatigue of Steel to Ni-based Alloys Dissimilar Joints
Laser Beam Directed Energy Deposition (L-DED) of an Fe-Si-B-Nb-Cu Soft Magnetic Alloy
Laser Beam Welding of Wrought and Additively Manufactured Ti-5Al-5V-5Mo-3Cr Alloys
Laser Welding of Al-Cu Interconnects for E-Mobility Applications: Effect of Beam Oscillation on Metal Mixing, Microstructure, and Mechanical Property
Linear Solid State Welding w/ NO Fusion Line. Fine Grained Base to Base Using 95% Less Energy
Machine Learning for GMAW Weld Quality
Machine Learning for Predicting Weld Quality and Properties in Resistance Spot Welding Process
Mapping of a Resistance Spot Weld Properties onto a Space Defined by Base Material Attributes
Mechanizing Self Shielded Flux Core Wire to Achieve Robust Toughness on Girth Welds in Pipeline Construction
Metallurgical Characterization of Rotary Inertia Friction Welded Dissimilar 422 Martensitic Stainless Steel to 4140 Low Alloy Steel Piston Joints
Methodology Development of Ultra-high Temperature Mechanical Performance of Additively Manufactured Refractory Alloys
Microstructural Heterogeneities in Electron Beam Additively Manufactured Haynes 282
Monitoring Torch Position and Weld Quality with Reversed Electrode Image during GTAW Process
Monitoring Weld Penetration using a Deep Learning Model Pre-trained from Filtered Current
My 40 Years as a Welding Engineer in the Oil and Gas Industry
Next Generation Double Electrode GMAW Processes for Precision Fillet Welding
Nickel Aluminum Bronze Weld Metal Microstructures in Wire Arc Additive Manufacturing with Cryogenic Cooling
Nondestructive Characterization of Grade 92 Steel Weld Microstructures using, Micro-resolution Ultrasonic Imaging System.
Numerical Modeling of Arc Plasma and Shielding Gas Flows in Wire Arc Additive Manufacturing of Tall Walls
Numerical Modeling of Resistance Spot Welding Processes and Liquid Metal Embrittlement Cracking
Numerical Modelling of Temperature and Velocity of WC-Co-Cr Particles in the HVOF Process using DJ2700 Gun and Hydrogen as a Fuel
Online Quality Monitoring Method in Gas Metal Arc Welding Based on Vision Camera and Laser Vision Sensor
Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems
Optimization and Characterization of FSpJ for Al Alloys and Polymeric Materials: Experimental and Numerical Investigations
OSU Faculty Overview-Metallurgy and Weldability
OSU Faculty Overview-Processes
OSU Faculty Overview - Design, Modeling and Nondestructive Evaluation
Overview of RW Projects for the Automotive Industry
Plenary Talk: Delta Ferrite and Rapidly Solidified Microstructure in Welding and Additive Manufacturing of Martensitic Steels
Practical Calculation of Cooling Rate, HAZ Width, and Thermal Features in Welding and Additive Manufacturing
Precipitation Kinetics in Additively Manufactured Alloy K-500 and Commission IV Activities
Predicting Laser Weld Variability in 304 Stainless Steel Resulting from Composition Variation
Process Advantages of Laser Hybrid Welding of Thick-walled Steel Structures of Wind Tower
Process Control of a Custom Designed Adaptive Weld Head
Reduction of Hot Cracking in Welded Overlays via Reduced Martensite Start Temperature
Robotic Path Planning for Wire Arc Additive Applications of Aerospace Aluminum Alloys
Robotizing Double-electrode GMAW by Learning from Human Welders
Shoring Up Long Lead Time Supply Chain Issues of Forgings and Castings using Advanced Manufacturing
SiC and Nickel-base Superalloy Dissimilar Joining using Multi-principal Element Alloy Fillers
Silicate-free Tandem GMAW for Shipbuilding Applications
Solidification Behavior and Microstructure Evolution in Dissimilar Electron Beam Welds between Commercially Pure Iron and Nickel
Solidification Behavior of Laser-wire Directed Energy Deposition Austenitic Stainless Steel
Standards for Laser Welding/Cutting
Stress Relaxation Cracking Susceptibility in 347H SS Welds and Their Repairs
The Ohio State University Welding Engineering Program - the First 75 Years
The Role of Diffusion Brazing Technology for the Repair of Gas Turbine Engine Components
The Role of Material Selection and Thermal Cycling on Tool Life in Refill Friction Stir Spot Welding
Thermal Faceting on the Ductility-dip Cracking Fracture Surfaces of Nickel-based Alloys and Stainless Steel – Occurrence, Characterization, and Implications for the Cracking Mechanism
Thermo-Mechanical Fatigue of Welding Defect-containing Boiler Water Walls
Thermodynamic and Kinetic Calculation of Stainless-steel Solidification – revisiting the WRC-1992 Diagram
Time-of-flight Imaging for Metrology in Wire-arc Additive Manufacturing
Ultrasonic Welding of Dissimilar Materials
Ultrasonically Assisted Resistance Spot Welding of Multilayer Foils in Battery Manufacturing
WE in the Power Generation Industry
Weld Vac – A Quiet, Clean Metal Removal System
Welding Engineering in the Aircraft Engine Industry
Welding in Space: Past, Present, and Future
Wobble Laser Beam Welding in Keyhole Mode
Title: Ultrasonic Assisted Soldering of Metallized Polymer Current Collectors for Li-Ion Batteries

Questions about ProgramMaster? Contact