Welding Simulation
Interactive physics-based simulation and 3D visualization tool for thermal welding processes and automated weld seam geometry estimation.
Technology Readiness Level
Technology Validated in Lab
Key components and software architecture modules are integrated and tested together in a controlled laboratory environment, establishing that disparate elements work together to achieve baseline performance.
Framework alignment: Standardized 9-level TRL (NASA / EU Horizon Europe).
Core Challenge
Predicting weld pool geometry (weld width and penetration depth) and transient heat-affected zones in arc welding traditionally requires either costly empirical trial-and-error experimentation or computationally prohibitive non-linear finite element method (FEM) simulations.
System Architecture
A lightweight, interactive Java engineering application combining analytical moving heat source models (extended Rosenthal solution with multi-source weaving discretization), fast numerical isotherm root-finding, and hardware-accelerated 3D OpenGL visualization.
Key Capabilities
- Analytical Thermal Field Modeling: Evaluates temperature distributions using moving point-heat formulations with parameterized welding speed, heat input, and thermal diffusivity.
- Torch Weaving Discretization: Simulates oscillatory torch motion through distributed discrete point-source superposition across parameterized bead widths.
- Automated Isotherm Search: Adaptive numerical root-finding that calculates maximum weld width and depth at critical liquidus/solidus melting boundaries.
- Interactive 3D OpenGL & Orthogonal 2D Views: Real-time rendering of spatial thermal contours and orthogonal cross-sections (XY, XZ, YZ planes) with dynamic parameter sliders.
Technology Stack
- Core Platform & GUI: Java 23, JavaFX Properties & Bindings, Swing & Docking Frames
- Thermal Physics & Mathematics: Rosenthal Heat Equation, Superposition & Weaving Discretization, Adaptive Root-Finding, Apache Commons Math
- Visualization & Rendering: JogAmp JOGL (OpenGL 3D), JFreeChart (2D Cross-Sections)
Verifiable Outcomes
- Instantaneous estimation of weld seam width and depth without expensive finite element computation.
- Interactive parameter exploration for heat input, torch velocity, and material properties with real-time visual feedback.
- Open-source research tool published on GitHub providing a modular architecture for welding process simulation.
