Recent developments in finite element simulations of the welding process

Welding is an integral manufacturing procedure for many components, some of which could not be produced without its application. Components that are subjected to high service temperatures in particular, where creep (and possibly high temperature fatigue and creep-fatigue interaction) is significant require well-defined material behaviour, and for all integral structural components, the lifetime requires adequate assessment. This paper provides an overview of the method and application of finite element welding simulations, and how the resulting information (e.g. residual stress, distortion and microstructural modification) can be used as input for life assessment analyses. Welding simulation results can also be fed into heat treatment models, where the material properties can evolve and the residual stresses relax and redistribute. Machining processes can also be modelled and the final results, covering the entire manufacturing process, can be obtained.