SMAW welding simulation

A ready-to-run finite element kit for Shielded Metal Arc Welding (SMAW) that predicts nodal temperature, thermal history, distortion, and residual stress. The workflow automates multi-pass material deposition (6 layers) and a moving weld heat source via Python, so you can focus on engineering decisions—not model plumbing.

This model is ideal for training, method development, and pre-study assessments that connect directly to industry practice (e.g., ASME-aligned integrity checks, burnthrough risk screening for in-service welding, and weld procedure planning).

What’s Included (Download Package)

• Abaqus/CAE model (.CAE) – fully set up geometry, steps, BCs.

• Abaqus input deck (.INP) – ready to submit.

• Python scripts (.py) – automate:

  • pass-by-pass element activation (material deposition for 6 layers),

  • moving arc/heat-flux application (double-ellipsoid/Goldak-style or equivalent),

  • time stepping, field output requests, and post-processing hooks.

• Example result fields (ODB) or plots (if supplied):

  • nodal temperature histories,

  • residual stress maps,

  • deformed shapes / contours.

You can adapt layer count, path, heat input, and dwell times from the script parameters.

Key Features

• Automated weld build-up: 6 sequential layers using activation to represent bead deposition.

• Moving heat source: parameterized arc power, travel speed, arc efficiency, and bead path.

• Thermo-mechanical coupling: temperature-dependent properties; plasticity for residual stress.

• Outputs you need: inner/outer surface temperatures, peak temperature maps, longitudinal/hoop residual stresses, and displacement.

• Clean, editable code: Python scripting designed for quick modification and reuse.

Applications

• ASME-aligned engineering studies: supports simulations used alongside ASME PCC-2 (in-service repair), ASME Section VIII (pressure vessels), and ASME B31.1/B31.3 (power & process piping) when paired with proper code checks.

• Burnthrough risk screening: use inner-wall temperature histories and local section softening as inputs to your burnthrough/pressure-containment checks.

• WPS development & training: explore sensitivity to heat input, travel speed, preheat/interpass, and bead sequencing.

• Method development: a starting point for adding CFD-refined heat-transfer coefficients, geometric variants (sleeves/branches), or alternative processes.

Note: This package does not replace required code calculations, inspection, or PE stamping. It provides physics-based FEA results to inform those activities.

Technical Details

• Solver: Abaqus/Standard (thermo-mechanical, transient).

• Process: SMAW; 6-pass sequence (editable).

• Boundary conditions: convection/radiation templates; pressure/constraints; easy to edit.

• Material models: temperature-dependent properties (placeholders provided—replace with your datasheet values).

• Scripting: Abaqus Python (clean functions to change bead path, speed, power, interpass times).

How You’ll Use It (Typical Steps)

1. Open the .CAE or run the .INP to verify baseline.

2. Edit Python parameters (arc power, efficiency, travel speed, layer timings, preheat/interpass).

3. Submit the job; review temperature and residual stress fields.

4. (Optional) Couple with your ASME checks (e.g., PCC-2 burnthrough screening, pressure-containment at locally heated zone).

Requirements

• Abaqus/CAE + Abaqus/Standard (modern version).

• Python environment shipped with Abaqus.

• Basic familiarity with editing Abaqus model parameters and running jobs.

License & Support

• For engineering/educational use. Not a certification tool.

• Responsibility for code compliance, inputs, and interpretation remains with the user.

• Light email support for install/run issues; customization available as a separate service.

What This Is Not

• A substitute for ASME code calculations, owner specs, or professional engineering stamping.

• A guarantee of burnthrough outcome—use your organization’s acceptance criteria and safety factors.

Author

Saman Hosseini — Welding & FEA practitioner focusing on weld thermal/residual stress simulation and applications aligned with ASME practice (PCC-2, Section VIII, B31.1/B31.3). Saman develops automated Abaqus/Python workflows for multi-pass welds, temperature mapping, and post-weld stress evaluation used in training, pre-study assessments, and project support.