Weld Bead Analysis in Copper-Copper Welding

Project Overview :

Conducted a comprehensive analysis to identify porosity zones and the shape of the weld bead in Copper-Copper welding for a global automotive company’s R&D center. The project aimed to optimize the welding process by simulating a conical heat source with multiple passes.

Key Contributions :

• Utilized CRADLE CFD (scSTREAM) to simulate the welding process with a conical heat source and 6 passes, analyzing porosity zones and weld bead morphology.

• Leveraged JavaScript scripts to model temperature-dependent viscosity and surface tension, ensuring accurate and realistic simulations.

• Provided critical insights into the welding process, enabling the R&D team to improve welding quality and efficiency.

Outcome :

• Delivered detailed analysis of porosity zones and weld bead shapes, contributing to enhanced welding process optimization.

• Demonstrated the effectiveness of advanced CFD techniques and scripting in addressing complex welding challenges, supporting the R&D center’s goals.

This project highlights expertise in welding simulations, heat source modeling, and scripting, showcasing the ability to deliver innovative solutions for automotive R&D challenges.

Tools : Cradle CFD (scSTREAM)