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CASiM² project: Multi-scale Modelling of a Fusion Weld

Researcher(s): Chinnapat Panwisawas, Yogesh Sovani, Richard Turner

Collaborator(s): Jeff Brooks, Hector Basoalto, Mark Ward, Hang Wang

The CASiM2 project is a joint University of Birmingham / Rolls-Royce plc / Airbus / the MTC collaborative venture, sponsored by the European Regional Development Fund (ERDF), aiming to promote the use of computational modelling techniques within the West Midlands region and assist local Small-Medium Enterprise businesses (SME's) to better understand manufacturing methods by these computational modelling methods.

Fusion weld techniques have been widely used in industries such as aerospace, power generation, automotive and energy, to fabricate their structures with high-integrity joining methods. These fusion weld techniques are typically electron beam welding, laser welding, TIG welding, MIG welding, other arc welding methods or pulsed welding. However, all fusion welding applications will inevitably induce distortions and residual stresses in to the structure close to the weld line. Whilst traditional experimental techniques can be used to measure the quantities of these fields, a computational model based upon FE methods could offer a greater understanding.

The project aims to take the exisitng finite element methods for welding distortion prediction, and significantly develop them. These developments include the prediction of weld pool size and shape using  computational fluid dynamics (CFD) methods within the open source software OpenFOAM, develop Cellular Automata (CA) calculations to link in to the Finite element models to predict grain structure during and after the welding operation, and link these to a plasticity code to develop models for the lifing of these critical parts.

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