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Cast-Designer Weld

The unique solution for complex large welding and assembly process, with full chain solution from the material →to process design →to simulation →to production and automatic optimization from welding parameters and assembly sequence

Cast-Designer WELD from C3P Engineering Software International Co., LTD. is the leading solution for the design, simulation and optimization of welding and welding assembly process, while taking into account all factors of design geometry, material behavior and welding process parameters.

Cast-Designer WELD is practice-oriented, fast and easy to use. The user can focus on the engineering related details of the welding process instead of dealing with the software operation.

Why Cast-Designer Weld?

Evaluate Residual Distortions

Weld distortion is a frequent problem in welding. Techniques like tack welding, fixturing, and advanced methods (pre-offset, trail cooling) can be optimized via simulation to predict and achieve zero distortion.

Minimize Residual Stresses

Residual stress impacts weldment service life. Cast-Designer WELD generates a 3D stress map for fatigue/creep analysis, optimizing design to avoid part rejection and enhance longevity.

Control the HAZ

Master the Heat Affected Zone (HAZ) to minimize stresses and deformations. Simulation ensures this sensitive zone remains narrow and controlled.

Predict the Real Weld Bead

Simulates material addition, making weld bead shape a true result of the process—not an assumption.

Study Geometry & Parameters

Optimize part geometry and process parameters early in design to avoid costly engineering changes.

Optimize Welding Sequence

User-defined sequencing and control of parameters (energy input, speed, material) for optimal weld quality.

Welding Processes

  • Arc welding (TIG/MIG/MAG …)
  • Laser welding
  • Friction Stir Welding
  • Electron-beam
  • Resistance spot welding
  • Brazing
  • Additive manufacturing
  • …

Analysis Results

  • Temperature field
  • Heating & cooling rate
  • Metal flow
  • Distortions
  • Stresses
  • Yield stress of the material
  • Plastic strain
  • Stress relief
  • Weld pool porosity
  • …

Key Benefits

  • Best-in-class result accuracy & stability
  • Understand welding effects on infrastructure prior to welding
  • Optimize weld sequencing to reduce distortion
  • Predict microstructure evolution
  • Obtain realistic thermal models
  • Cost optimized

Welding Design Solutions

WELDING CALCULATOR - WELDABILITY CHECK

The weldability (also known as joinability) of a material refers to its ability to be welded. Many metals and thermoplastics can be welded, but some are more easily welded than others. A material's weldability is used to determine the welding process and to compare the final weld quality with other materials.

A built-in calculator helps users calculate many useful results for weldability analysis, supporting the planning and optimization of welding tasks including weldability, cooling time, preheating temperature, and required filler metal quantities.

CE, NiEQ, CrEQ
PCM, CEN, HCS
Reheat crack
Phase balance, FNA
Cooling time t8/5
Pre-heat temperature
AC1, AC3, MS temp
HAZ hardness
Welding Example 1

Weld calculator interface

Welding Example 1

Schaeffler diagram

SMARTWELD OPTIMIZATION TOOLS

The SmartWeld optimization and analysis tools have been developed to perform weld analysis and provide optimal weld schedules for CO2 continuous wave laser welding, pulsed Nd:YAG laser welding, and non-consumable arc welding processes.

Welding Example 1
Input power: 2980 watts
Welding speed: 5.3 mm/sec
Width of weld: 6.74 mm
Penetration depth: 3.37 mm
Melt efficiency: 0.299
Welding Example 2
Input power: 2240 watts
Welding speed: 4.2 mm/sec
Width of weld: 6.22 mm
Penetration depth: 3.11 mm
Melt efficiency: 0.268

Predictive

  • Science-based process models enable optimized automated weld procedures
  • Virtual manufacturing enables "what if?" scenario testing
  • Eliminates need for multiple test welds to determine parameters

Investigative

  • Solves welding problems by analyzing efficiencies and figures of merit
  • Universal models applicable to many weld processes
  • Provides deeper understanding of welding processes

Optimization Methodology

The optimization methodology consists of mixed genetic and gradient-based algorithms to query semi-empirical and nonlinear algebraic models. The optimization output provides heat-input-efficient welds for user-specified weld dimensions. User querying of all weld models is available to examine sub-optimal schedules.

Advanced Welding Technology

Comprehensive welding simulation solutions integrating advanced heat source modeling, multi-pass optimization, and weld pool dynamics

HEAT SOURCE MODELING

CAST-DESIGNER WELD incorporates an extensive heat source database for various welding processes, requiring only basic parameter inputs for accurate simulation. Our advanced thermal modeling captures the complex physics of different welding techniques.

Double ellipsoid heat source
2D Gaussian heat source
3D Gaussian heat source
3D uniform heat source
3D Conical heat source
3D Print heat source
Combined heat source
FSW heat source

LINE HEAT SOURCE OPTIMIZATION

Our proprietary line heat source technology accelerates simulation times by 10-30x while maintaining accuracy. Users define heat source length parameters to balance computational efficiency with result precision.

BIRTH AND DEATH ELEMENT TECHNOLOGY

Advanced element activation/deactivation algorithms precisely simulate weld bead deposition, significantly enhancing simulation accuracy for additive welding processes.

MULTI-PASS WELD DESIGN & SIMULATION

Critical for steel construction and pressure vessels, multi-pass welding presents significant challenges with defects and residual stresses that impact structural integrity and fatigue life.

Traditional trial-and-error approaches are impractical when evaluating thousands of possible welding sequences. Our solution combines:

  • Automated pattern generation for distortion control
  • Advanced surrogate modeling for rapid evaluation
  • Multi-objective optimization for stress/distortion minimization
  • Quantitative comparison of welding sequences

The system evaluates thermal cycles, phase transformations, and mechanical responses to identify optimal welding patterns from tens of thousands of possible configurations.

Multi-pass weld layout design

JOINT DATABASE

Welding joint database

CAST-DESIGNER WELD includes a comprehensive joint database covering:

  • MAG/MIG steel welding configurations
  • Laser weld joint profiles
  • Aluminum welding geometries
  • 30+ standard joint types

The database supports:

  • Heat transfer calibration for assembly simulations
  • Validation against international standards (AWS, EN, JIS, GB)
  • Custom joint creation for specialized applications
  • Process parameter optimization

WELD POOL SIMULATION

Our advanced CFD solver captures the complete weld pool physics including:

  • Surface tension effects (curvature and Marangoni)
  • Buoyancy-driven fluid flow
  • Free surface deformation
  • Phase change dynamics
  • Keyhole formation (for laser welding)

The simulation provides detailed visualization of:

  • Temperature gradients
  • Velocity fields
  • Solidification fronts
  • Microstructure development
Weld pool temperature and velocity

Resistance Spot Welding Technology

Advanced simulation solutions for optimal spot welding performance and quality control

Resistance spot welding permanently joins metal parts by melting and fusing materials through localized heat generated by electrical resistance. The process creates a strong metallurgical bond as the molten materials cool rapidly under electrode pressure.

Spot welding process

Heat generation follows Joule's Law (Q=I²Rt), where resistance to current flow between electrodes creates localized melting. CAST-DESIGNER WELD precisely simulates this thermo-electrical-mechanical process for optimal parameter selection.

Welding Simulation in Industry (Lobe Curve)

The weldability lobe graphically represents acceptable welding parameter ranges that produce quality welds. Simulation identifies the optimal process window to:

Achieve desired weld quality
Reduce power consumption
Minimize consumable wear
Optimize joint strength
Spot Welding Lobe Curve

Weldability Lobe Curve

Welding current table

Current Parameter Table

Modern manufacturers rely on weldability lobe simulation to select parameters that meet strict joint stretch requirements while maximizing electrode life and energy efficiency.

Spot Welding Simulation Modeling

CAST-DESIGNER WELD provides comprehensive 3D simulation of the spot welding process with advanced modeling capabilities:

Full 3D thermo-electrical-mechanical simulation
Blank sheet & electrode material databases
Template-based quick setup
Multi-layer sheet support (1.0mm+0.8mm+1.2mm)
Nugget growth visualization
Experimental validation tools
Real spot weld

Actual Spot Weld

Simulation model

Simulation Model

Multi-layer weld

3-Layer Assembly (1.0+0.8+1.2mm)

Nugget comparison

Simulated vs Actual Nugget

Spot Weld Process Simulation Examples

Advanced visualization of the spot welding thermal cycle and nugget formation:

Temperature distribution

Temperature Distribution

Nugget growth

Nugget Formation & Cooling

The simulation captures key process phenomena including contact resistance changes, thermal expansion, and phase transformations during heating and cooling cycles.

Smart Welding Assembly Technology

Advanced thermo-mechanical simulation for welding distortion prediction in complex assemblies

The Smart Welding Assembly module in Cast-Designer WELD utilizes fast thermo-mechanical coupled simulation methods to predict assembly distortions in large, complex welded structures. The solution combines computational efficiency with industrial-grade accuracy for practical engineering applications.

Lagrange FEM method with industry validation
Detailed welding parameter inputs
Intuitive interface with short learning curve
Welding sequence optimization
Flexible boundary conditions
Rapid modeling and simulation
Smart Welding Assembly Overview

Advanced Simulation Approaches

Inherent Strain Method

Originally proposed by Ueda for residual stress measurement, this elastic FE simulation method has become the industry standard for predicting welding distortion in large structures.

Advantages
  • Extremely fast simulation times
  • Proven industrial accuracy
  • Effective for large assemblies
Limitations
  • Requires validation data
  • Less precise for complex thermal gradients
  • Limited nonlinear material behavior

Smart Assembly's Thermal-Mechanical Approach

Our enhanced methodology applies thermal loads directly based on welding process parameters for improved accuracy:

  1. Calculate thermal distribution from current, voltage, and speed
  2. Derive inherent stress from thermal-mechanical relationships
  3. Process welding sequences individually or collectively
Key Benefits
  • Eliminates local-global model requirements
  • Supports diverse welding processes
  • 30-50% more accurate than standard methods
  • Simplified model setup

Weld Line & Layout Design Tools

Intuitive free-draft interface with mouse-click operation
Smart edge snapping for continuous weld line creation
Import designs via CSV or DXF (AutoCAD compatible)
Comprehensive weld bead management tools
Template saving for design reuse
Multi-design plan comparison
CAD wire generation from bead designs
Weld Line Design Interface

Welding Optimization Technology

Advanced multi-criteria optimization using AI-driven methods to achieve optimal welding results

CAST-DESIGNER optimizer executes multi-criteria non-linear optimization using Design of Experiments (DOE), Genetic Algorithms (GA), and Particle Swarm Optimization (PSO) - advanced artificial intelligence techniques for industrial applications.

Multi-Objective Optimization Capabilities

Multiple Criteria Targets

  • Distortion minimization
  • Displacement control
  • Stress/strain reduction
  • Temperature management
  • Welding speed maximization
  • Residual stress minimization

Multiple Design Variables

  • Parametric CAD geometries
  • Weld bead dimensions
  • Material properties
  • Welding velocity
  • Current/voltage parameters
  • Fixture conditions

Advanced Optimization Engine

The system intelligently evaluates each iteration's results (distortion, stress, etc.) and automatically adjusts variables (velocity, sequence, etc.) until targets are achieved. Complex user formulas are supported without programming, and parallel optimization dramatically reduces lead times.

1. Sequence Optimization

  • Find optimal welding sequence
  • Minimize distortion
  • Reduce residual stress
  • Improve structural integrity

2. Process Optimization

  • Optimize welding parameters
  • Determine ideal material properties
  • Calculate optimal welding speed
  • Fine-tune current/voltage

3. Part Optimization

  • Optimize part dimensions
  • Determine ideal feature locations
  • Achieve defect-free welding
  • Improve manufacturability

4. Design of Experiments

  • Assess design variable impacts
  • Full factorial and Taguchi methods
  • Custom condition formulas
  • Create approximation models

5. Automatic Optimization

  • Parallelized optimization
  • Multi-objective optimization
  • AI-driven parameter adjustment
  • Fast convergence algorithms

6. Results Analysis

  • 2D/3D visualization tools
  • Surface and contour mapping
  • Statistical analysis (ANOVA)
  • Pareto frontier visualization
  • Excel integration

Welding Optimization Case Study

Vehicle Chassis Bracket Welding Sequence Optimization

Study distortion patterns in standard welding process
Evaluate multiple welding sequence scenarios
Identify optimal sequence with minimal distortion
Achieve 42% distortion reduction compared to initial sequence
Initial Welding Sequence

Initial Welding Sequence

Optimized Welding Sequence

Optimized Welding Sequence

Welding Case Studies

Real-world applications demonstrating our welding simulation capabilities across industries

1. Automotive Chassis Welding

Welding of thick/thin-walled chassis and body-frame parts

For Automotive OEM and selected suppliers, railway and aerospace industry.

Parts typically have 5-100 welding joints with industry trends reducing joint counts
Lightweight aluminum materials present welding challenges: higher power requirements and greater distortion than steel
Simulation goals: predict/minimize distortions while considering mechanical properties and residual stresses for fatigue analysis
Temperature distribution

Temperature distribution

Residual stress after welding

Residual stress after welding

Distortion after welding

Distortion after welding

2. Motorcycle Frame Welding

Thin wall frame assembly

Primary objective: distortion minimization through clamping tool optimization and process parameter adjustment
Fatigue life prediction incorporating residual stresses and stress gradients
Welding repair process optimization to reduce failure risks
Residual stress after welding

Residual stress after welding

Distortion after welding

Distortion after welding

Distortion after welding (enlarged)

Distortion after welding (enlarged)

3. Railway Structural Welding

Large structure assembly with multi-pass welding

Distortion repair accounts for 20-40% of manufacturing costs in large welded structures
Numerical simulation replaces costly prototyping and destructive testing
Residual stress control critical for fatigue life and crack prevention
Temperature distribution

Temperature distribution

Residual stress after welding

Residual stress after welding

Bogie frame distortion

Bogie frame distortion

4. Heavy Industry Welding

Shipbuilding and construction equipment

Multi-pass welding challenges in massive structural components
Cost reduction through simulation avoiding physical prototypes
Residual stress management for structural integrity
Temperature distribution

Temperature distribution

Temperature distribution

Temperature distribution

Residual stress after welding

Residual stress after welding

Distortion after welding

Distortion after welding

5. Shipbuilding Welding

Marine and construction equipment

Large-scale welding challenges in marine environments
Economic benefits of simulation for massive components
Structural reliability through stress management
Temperature distribution

Temperature distribution

Residual stress after welding

Residual stress after welding

Distortion after welding

Distortion after welding

6. Fatigue-Critical Welding

Residual stress control for dynamic components

ITER is the world’s largest fusion experiment. 35 nations are collaborating to build and operate the ITER Tokamak, the most complex machine ever designed, to prove that fusion is a viable source of large-scale, safe, and environmentally friendly energy for the planet.

Applications: frame/suspension systems, engine/transmission components, aero-engine turbines
Precision distortion control for critical assemblies
Residual stress optimization for fatigue performance
Actual assembly

Actual assembly

Temperature distribution

Temperature distribution

Residual stress after welding

Residual stress after welding

Large-scale distortion

45m x 68m x 28m assembly

7. Multi-Pass Welding

Nuclear, energy, and marine applications

Critical applications in nuclear, shipbuilding, and pressure vessel industries
Reliability-focused process optimization
Cost-effective simulation replacing destructive testing
Pipe multi-pass welding

Pipe multi-pass welding

Multi-pass weld layout

Weld layout design

First pass temperature

First pass temperature

Final pass temperature

Final pass temperature

Residual stress after welding

Residual stress after welding

NESTech Services and Products

Why Choose NESTech as your CAD CAE Partner?

+ Drawings Created
+ Simulations done
+ Team Members
+ Years of Experience
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RICH EXPERIENCE

 We bring 25+ years of rich experience to every project, ensuring exceptional results and unparalleled reliability.

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ON-TIME DELIVERY

 With meticulous planning, streamlined processes, and a dedicated team, we ensure that every project is completed promptly and efficiently

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EXCELLENT COLLABORATION

 We foster a culture of teamwork, communication, and mutual respect, ensuring that every project benefits from the diverse perspectives and expertise of our team members.

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COST EFFECTIVENESS

  With a multitude of projects Completed and catering to various industries, we have demonstrated excellent business results at lower cost with our domain expertise.

Some of the Cast-Designer Software Customers