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1
Abaqus Welding Analysis

Presented by: Philip Williams (phil@simutech.com.tw)
SIMULIA Roadshow
21st and 22nd July 2015
Copyright 2015 Simutech Solution Corp. All Rights Reserved.
Overview
Introduction
Adding Weld Material
Multi-Physics Capabilities
Material Properties With Temperature
The Abaqus Welding Interface (AWI)
Methodology
Using AWI Tool
Welding Analysis in Abaqus
Join sections together at high temperature during an analysis

Add material during analysis
Interaction between temperature and stress/displacement
Temperature dependent properties
Assess the residual stresses and distortion of the model

In Abaqus, we cannot create elements during an analysis
Define all elements in initial model
Remove using *model change, remove
Add back in when required using *model change, add
Initial Model
*Model Change,
Remove
Pass 1
Pass 2
Pass 3
Pass 4
Pass 5
Pass 6

Simulate a continuous procedure
Separate weld into smaller chunks progressively add
chunks over several steps
Gets confusing as model gets bigger
Use the AWI plug-in to help set up model
Lay down a complete pass in one step

Use subroutines to update material properties and loading
conditions as function of time or position
Material properties (UFIELD or USDFLD)
Moving heat flux to represent moving torch (DFLUX)
Film coefficients (FILM)
Conduction of heat between weld and base materials
(GAPCON)
Defining subroutine is more advanced
Requires Fortran programming
Sequentially coupled
thermal-stress analysis
Temperature fields are calculated first and read into stress

analysis
Thermal analysis not affected by displacements
Fully-coupled
thermal-stress analysis
Temperatures and stresses calculated simultaneously

Thermal analysis can be affected by displacements
Coupled thermal-electrical
analysis followed by stress
analysis
Fully-coupled
thermal-electrical-stress
analysis
Electric potential and temperature fields solved simultaneously

then temperatures read into stress analysis
Thermal-electrical analysis not affected by displacements
Stress/displacement, electric potential and temperature fields

solved simultaneously
Thermal-electrical analysis can be affected by displacements
Multi-pass weld:
Sequentially Coupled Thermal-Stress Analysis
Spot weld:
Thermal-Electrical-Stress Analysis
Multi-pass Weld Thermal-Structural Analysis
Kobayashi and Mihara, 2014
For this presentation we will consider sequentially-coupled thermal-stress analysis

Material Properties With Temperature

Accuracy depends on quality of
material properties
May be temperature dependent
Thermal analysis
Conductivity
Specific heat
Stress analysis
Density
Elastic
Expansion
Plastic
Anneal temperature
Latent heat
Material Properties Anneal Temperature

Models effect of melting and resolidification
Above the anneal temperature:
Material loses hardening memory
Equivalent plastic strain drops to zero
Assumes perfectly plastic behaviour
Requires Mises, Johnson-Cook or Hill plasticity

Plastic strain
With Anneal temperature definition Without Anneal temperature definition

10
Material Properties Anneal Temperature

Plastic strain
With Anneal temperature definition:

Reduction in plastic strain in region
being heated
Without Anneal temperature definition:
Plastic strain is not reduced
First pass completed.

Heat base material and existing weld
before start of next pass.
11
Material Properties Latent Heat

Large change in internal energy
during phase change
Analysis becomes non-linear
Requires density definition
Define:
Latent heat per unit mass
(mJ/tonne),
Solidus temperature,
Liquidus temperature
Temperature (C)
With Latent Heat definition:

As weld cools, it must change
state from liquid to solid. This
releases energy, and so the
model cools more slowly.
Without Latent
Heat definition:
Model cools more
quickly
12
The Abaqus Welding Interface

The Abaqus Welding Interface (AWI) is a
useful tool for setting up a welding analysis
Plug-In for Abaqus CAE
AWI Tree
Takes the user step by step through the
process of defining weld chunks and passes
Tasks have to be done in order
Colour-coding of beads, chunks and passes

Operate on thermal analysis model
Stress analysis model is created at end and
is a copy of thermal analysis model
13
AWI Methodology
Sequentially-coupled thermal-static analysis
Thermal analysis first
Read temperatures into stress analysis
Weld beads are broken down into discrete chunks and added
over several steps
Approximates the continuous flow over time
Can consider multiple welds and multiple passes
14
Methodology Thermal Analysis
Remove welds
Step 1
*Model change,
remove
Simulate weld
torch
Transient heat
transfer step
Heat region to
which chunk will
be added
Base material
and/or previously
added weld
material
Activate weld
chunk
*Model change,
add
Weld material
initially at melting
temperature
Film and radiation
surfaces updated
Optional cooling
At the end of pass
Transient cooling
or
Steady state heat
transfer step
cooling to constant
temperature
15
Methodology Thermal Analysis

(video)
Single pass weld
Pipe weld with multiple passes
Multi-pass weld
16
Using AWI Tool

Create or import CAE
model
Model creation
Weld creation
Pass controls assignment
Pass creation
Job control assignment
Job creation
17
Using AWI Tool
Create or import CAE model
3D or 2D planar model
Create or
import CAE
model
3D welds ideally swept or

extruded
Model
creation
Base material and welds

must all be in one part
Weld creation
Pass controls
assignment
Pass creation
Nodes are shared between base material and weld
Partition the part as required

Include partitions for individual beads and chunks if possible
(welds can be defined using elements or geometry)
Create and assign model and section properties.

Job control
assignment
Job creation
Weld material properties must be defined over a range of temperatures,

including melt temperature and torch temperature
Assemble and position the model as required

Create mesh on whole model and assign element types
18
Using AWI Tool

Create or
import CAE
model
Model
creation
Weld creation
Pass controls
assignment
Model creation
Choose Abaqus model and

part to use
Assign base material and
section
Specify British or SI units
(sets defaults for some
parameters)
Pass creation
Job control
assignment
Job creation
19
Using AWI Tool
Weld creation
Assign weld temperature

Create or
import CAE
model
Assign regions of model to weld

beads
Model
creation
Multiple welds can be defined

(in same part)
Weld creation
Each weld may have multiple

beads
Pass controls
assignment
Pass creation
Job control
assignment
Job creation
20
Using AWI Tool
Weld creation
For swept or extruded geometry:

Create or
import CAE
model
Model
creation
Weld creation
Pass controls
assignment
Pass creation
Job control
assignment
Cell extrusion
Pick cell face and specify
number of cells in chunk
Element extrusion by cell face

Pick cell face and specify
number of elements in chunk
Element extrusion by element

face
Pick element faces for each
bead and specify number of
elements in chunk
Job creation
If geometry not swept, or weld not

continuous:
Cell/Element picking
Pick individual cells/elements for
each chunk
21
Using AWI Tool
Weld creation
Colour-coding tool to identify beads and chunks

Create or
import CAE
model
Use highlighting
tool to show beads
and chunks
Model
creation
Weld creation
Pass controls
assignment
Pass creation
Job control
assignment
Job creation
22
Using AWI Tool
Create or
import CAE
model
Model
creation
Weld creation
Pass controls
assignment
Pass creation
Job control
assignment
Apply Torch step

Job creation
Specify analysis controls
Specify torch application ramp or ramp and hold
23
Using AWI Tool
Create or
import CAE
model
Model
creation
Weld creation
Pass controls
assignment
Pass creation
Job control
assignment
Film and radiation properties

Job creation
Surfaces for beads and base material are updated in each step
Film properties applied to other surfaces remain constant
24
Using AWI Tool

Create or
import CAE
model
Model
creation
Weld creation
Pass creation
A weld pass is a number of weld chunks being laid

down in a step
Multiple beads or chunks from a single or multiple welds can be
laid down in a single pass
For 2D models, a pass is one or more entire weld beads
Assign weld beads to weld passes

Pass controls
assignment
Manually pick cells or elements to select chunks
Pass creation
Pass Manager
Job control
assignment
Once passes have been generated, we can add

additional analysis steps as required
Job creation
25
Using AWI Tool
Pass creation
Pass Manager
Create or
import CAE
model
Model
creation
Weld creation
Pass controls
assignment
Pass creation
Job control
assignment
Job creation
Pass
chunk
selection
Passmanager
managerwith
withautomatic
individual
chunkchunk
selection
selection
by bead
weld
26
Using AWI Tool
Job control assignment
Specify job names

Create or
import CAE
model
Model
creation
Choose element types

Specify bead removal for
stress model
Pass level
Weld creation
Pass controls
assignment
Pass creation
Job control
assignment
Elements stay in analysis with low

stiffness until activated
Remove then activate elements in each
pass
Model level
All weld elements removed at start of
stress analysis
Activate elements in each pass
Job creation
27
Using AWI Tool Job creation

Builds stress model
Create or
import CAE
model
Model
creation
Weld creation
Defines steps for heat transfer model
Model change definitions
Thermal loads
Film and radiation interactions
Defines steps for stress model

Pass controls
assignment
Pass creation
Job control
assignment
Model change definitions
Temperature field definitions from heat transfer analysis
Further changes can be made to models
For example: add boundary conditions to stress model
These changes may be lost if the job creation is run again
Job creation
28
Advantages Of Using AWI

Methodology requires:
Many steps to introduce weld gradually over time,
with additional cooling steps
Each time a chunk is added, model requires
definition of:
Separate element sets
1 or 2 heating steps
1 or 2 steps for model change
New film and radiation surfaces on weld and
base material
As the model gets larger, quickly becomes

unmanageable
Manual definition is time-consuming and errorprone
Tasks are repetitive ideally suited to plug-in
29
Summary
Analyse welding process to get accurate prediction of residual
stresses and distortion due to temperature gradients
There are options within Abaqus for:
Conducting multi-physics analyses
Adding material during an analysis
Including nonlinear, temperature dependent material properties
The Abaqus Welding Interface (AWI) will guide you through

the procedure, reduce the set-up time and automate many of
the repetitive tasks

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1

Abaqus Welding Analysis

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Welding Analysis in Abaqus

Join sections together at high temperature during an analysis

Assess the residual stresses and distortion of the model

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Adding Weld Material

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Adding Weld Material

Lay down a complete pass in one step

Temperature fields are calculated first and read into stress

Temperatures and stresses calculated simultaneously

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Electric potential and temperature fields solved simultaneously

Stress/displacement, electric potential and temperature fields

Multi-pass Weld Thermal-Structural Analysis

Kobayashi and Mihara, 2014

For this presentation we will consider sequentially-coupled thermal-stress analysis

Material Properties With Temperature

Material Properties Anneal Temperature

Requires Mises, Johnson-Cook or Hill plasticity

With Anneal temperature definition Without Anneal temperature definition

Material Properties Anneal Temperature

With Anneal temperature definition:

First pass completed.

Material Properties Latent Heat

With Latent Heat definition:

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

The Abaqus Welding Interface

Colour-coding of beads, chunks and passes

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Can consider multiple welds and multiple passes

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Methodology Thermal Analysis

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Methodology Thermal Analysis

Single pass weld

Pipe weld with multiple passes

Using AWI Tool

Using AWI Tool

Create or import CAE model

3D welds ideally swept or

Base material and welds

Nodes are shared between base material and weld

Partition the part as required

Create and assign model and section properties.

Weld material properties must be defined over a range of temperatures,

Assemble and position the model as required

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Using AWI Tool

Choose Abaqus model and

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Using AWI Tool

Assign weld temperature

Assign regions of model to weld

Multiple welds can be defined

Each weld may have multiple

Copyright 2015 Simutech Solution Corp. All Rights Reserved.

Using AWI Tool

For swept or extruded geometry:

Element extrusion by cell face