Automatic Laser-based Geometry Capture for Finite Element Analysis of Weld Beads

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes
• Computational Mechanics

Background:

• Fusion welding demands precise control over distortion and residual stress in high-value manufacturing.
• Current finite element analysis (FEA) models often use simplified geometries, leading to inaccurate predictions of welding-induced deformation.
• Accurate geometric representation is crucial for reliable FEA in fusion welding.

Purpose of the Study:

• To develop a protocol for capturing the true geometry of weld bead deposition.
• To enable rapid integration of captured geometry into finite element analysis (FEA) workflows.
• To improve the accuracy of FEA predictions for distortion and residual stress in fusion welding.

Main Methods:

• Utilizing a laser scanning system to capture the precise shape of a single weld bead.
• Developing a method to convert scanned geometric data into a format compatible with FEA software.
• Implementing a protocol for direct incorporation of captured geometry into FEA models with minimal user input.

Main Results:

• A protocol for accurate geometric data acquisition of weld bead deposition was established.
• The captured geometry was successfully converted for immediate use in FEA.
• The method allows FEA models to be populated with geometries representative of actual weld depositions.

Conclusions:

• The described protocol enhances the fidelity of FEA models by incorporating true weld bead geometry.
• This approach facilitates more accurate prediction and control of distortion and residual stress in fusion welding.
• The method offers a significant improvement over traditional FEA approaches relying on idealized geometries.