Engineers Develop Method to Predict Metal Deformation During Welding Using Simulation

During the construction of large metal structures, engineers often face the challenge of deformation in sheet elements. Even minor deviations in geometry can lead to a redistribution of internal stresses, ultimately causing waves, bends, and other defects. These structural changes can accelerate wear, reduce strength, and increase the risk of structural failure.

The causes of such changes are varied: uneven heating, residual stresses after welding, assembly errors, or the impact of external forces. Each of these factors can create areas of compression and tension, negatively affecting the object’s performance and durability.

To address this issue, specialists at UST Inc. employed the finite element method, which enables simulation of the metal sheets’ behavior at the design stage. Using digital models, engineers set material parameters, weld seam configurations, fastening conditions, and external influences. This approach allows them to predict in advance where hazardous zones might form and how the structure will perform under load.

During the study, a virtual model of the sheet element was created, taking into account all key parameters: from geometry to residual stresses. The analysis showed that the main causes of deformation are temperature fluctuations, uneven gaps between parts, and insufficient joint rigidity. This data made it possible to identify the most vulnerable areas and suggest ways to strengthen them.

The next stage involved step-by-step adjustments to the design. First, engineers took precise measurements of the sheet’s geometry and incorporated them into the model. Then, various welding and fastening options were simulated to assess the impact of each parameter on the final shape of the element. Based on the results, specialists suggested changing the span length, increasing the number of mounting points, and adjusting the welding mode. In some cases, additional stiffening elements or counter welds were added to compensate for arising stresses.

After making changes to the design, a repeated analysis confirmed a reduction in maximum stresses and a closer match of the sheet’s shape to the calculated one. This approach helped keep deviations within acceptable limits and increase the reliability of the entire system.

The practical value of this method is clear for companies working with large welded structures—from bridges to industrial buildings and transport highways. Using digital modeling not only reduces defect correction costs but also extends the lifespan of structures. Engineers can test the effectiveness of various solutions in advance and choose the optimal option without the need for expensive modifications on the actual site.

The experience of UST Inc. specialists shows that modern modeling technologies are becoming an essential part of designing and building complex metal structures. A systematic approach to analyzing and adjusting parameters helps minimize risks and ensures high quality of the final result.