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Welding and Heat Treatment

December 2017

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SYSWELD general introduction

• With this latest release, ESI has enhanced the welding & heat treatment simulation capabilities of SYSWELD2017 to secure process feasibility and security, to control material characteristics and residual stresses, to keepdistortion within specified tolerances, and to improve the performance of the product.

• The release includes new specific meshing capabilities to strongly reduce the time needed to create dedicatedmeshes for weld and heat treatment.

• To better support multi-pass welding, SYSWELD 2017 provides automatic control of the interpass temperaturebetween each weld, ensuring better component integrity with a direct control of phase proportion and stresses.

• The new version also supports new manufacturing processes, including spot welding using spacers, friction stirwelding and carbonitriding.

• New functionality allows the smart transfer of dedicated data from one simulation discipline to another, so thatcomplete manufacturing processes can be simulated and used as input for performance.

• Furthermore, users of SYSWELD benefit from new core technologies to support the treatment of very largemodels, and to minimize the output file size.

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ESI SYSWELD Welding Simulation SolutionSingle Pass Arc

Welding

Multi Pass Arc Welding

Laser Welding

Friction Stir Welding

Spot Welding

Post Weld Heat Treatment

Electron Beam Welding

Weld Grain Modeling

Physics

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ESI SYSWELD Heat Treatment Simulation Solution

Quenching

Carburizing Nitriding

Nitro Carburizing Induction Hardening

Weld-HT Chaining Solution

Cast-HT Chaining Solution

Forge-HT Chaining Solution

HT Machining Chaining Solution

Stamp-HT Chaining Solution

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ESI SYSWELD Welded Assembly Simulation Solution

Stamp Weld Assembly Chaining Solution for Distortion Control

Stamp Weld Assembly Durability Chaining Solution for Fatigue Performance Improvement

Seam & Spot Weld Rupture Chaining Solution for Crash Performance Improvement

Weld Sequence

Optimization

Fatigue Analysis

Crash Analysis

Stamping

Spot Welding Hardness Spot Shear Test

Welding

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Complete welding & Heat Treatment solution

Mesh Material db Processes Analysis

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Heat treatment

December 2017

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And the physics

The Heat Treatment processes

• Through Hardening

• Quenched Hardening

• Carburizing

• Nitriding

• Carbonitriding

• Induction hardening

• …

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Complete solution from material management, mesh, process set up and analyses

Material Management

CAD Handling

CAD 2 MESH

Heat Treatment

Engineering

Analyses

Optimization

Material Data Manager

Visual MeshVisual Heat Treatment

Visual Viewer

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Dedicated platform to guide the end user

Visual Heat Treatment

• Visual Heat Treatment, the complete workflow is represented as different steps andyou are efficiently guided to complete the set up with minimum input

• Project Description• Global Parameter• Component Properties• Heat Treatment Process• Clamping Condition• Loads and Deformations• Solution Parameter

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For large model management

Strong Thermal Mechanical Coupling

• The main purpose of virtual simulation is to predict accurately thebehavior of the product either qualitatively or quantitatively, ascloser as possible to the reality.

• Coupling of thermo-metallurgical and mechanical computationsbrings the prediction of simulation closer to the real worldscenario.

• This new feature is of great help in storing only important cardsas the computation is in process loop and as we do not need tostore all thermal out put to do the mechanical computation.

• It allows you to treat very large model without dealing with Gb ofout put files.

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Where it can be defined in Visual?

User Defined Results Storage During Computation

• Industrial users are requested to build very large models with hundreds of thousands ofelements and nodes, which lead to lengthy computation, thus it is very important to check andanalyze key thermal and mechanical results during the computation without waiting for the end ofthe computation.

• With this new version, in order to reduce the results file size, you can choose the requiredresults before to start the computation. From a dedicated dialog box, you can customize theoutput result file based on your need and optimize the output file size by keeping only relevantresults on specific time

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Accurate prediction of phase transformation based on automatic calibration

IT and CCT Diagram Automatic Calibration

• In the database, a specific tool has been defined to allow automatic calibration of CCT and ITdiagram. After calibration user can display and compare the computed diagram with theexperimental one.

• Easy to use it allow accurate simulation of phase transformation

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Available in Visual Heat Treatment

Carbonitriding

• Carbonitriding is similar to gascarburization with the addition ofammonia to the carburizingatmosphere, which provides asource of nitrogen. Nitrogen isabsorbed at the surface anddiffuses into the workpiece

• Carbonitriding tends to be moreeconomical than carburizing,and also reduces distortionduring quenching. The lowertemperature allows oilquenching, or even gasquenching with a protectiveatmosphere.kpiece along withcarbon.

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Heat Exchange coefficient

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Time dependency for diffusion coefficient

• In some processes the decarburization is not so important and to well control it, it is then needed to define the diffusion coefficient based on time dependency.

• In the new version a new button named “Coefficient Curve” has been added. By selecting it, the classic “Visual Plot Editor” dialog box is opened and the user can define the diffusion coefficient based on time during the phase of enrichment and diffusion.

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Heat Treatment simulation restart

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• This process can be simulated with the current version of visual Heat treatment.Several cycles can be imported directly using Visual Plot Editor in .csv format.Accordingly the evolution of the carbon profile will be computed.

Low pressure carburizing

Carbon Activity Carbon Content

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Incremental Clamp Release…

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Rigid clamps are released gradually

• When there are number of rigid clamps for a flimsy model in welding simulation, abrupt release of rigid clamps will have an impact on convergence of the simulation. Therefore it is important to simulate the real time scenario where the rigid clamps are removed gradually in sequence as the welding process is completed.

• To support this condition “Incremental Clamp Release” feature has been implemented.

• The release duration of the clamp that is released can be given by the user. This option is currently available only in Welding Advisor.

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Nitruration

December 2017

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Précipitation des nitrures de chrome ( CrN) Appauvrissement de la couche nitruréeen carbures de chrome Cr7C3

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Cr

N

C

Activité des éléments chimiques N, C , Cr (%)

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Evolution de la fraction du précipité CrN (%) en fct du Temps

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Evolution de la fraction du précipité Cr7C3 (%) en fct du Temps

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Capability & AvailabilityWeld Quality, Heat Treatment, Assembly

www.esi-group.com/Welding

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Thank You