Weld residual stress and distortion are inevitable during welding due to rapid local heating and cooling, high-temperature material reactions and weld-fixture effects. To predict weld residual stress and distortion, an engineer has to understand welding processes and the finite element analysis method. It is difficult for an engineer without finite element background to calculate the weld residual stress and distortion. With the development of weld modeling technology, automatic meshing generation, and high performance computation, a web-based analysis tool (E-Weld Predictor), was developed to predict weld residual stress and distortion. This allows an engineer to calculate the weld residual stress and distortion on line. The engineer does not need to have finite element analysis knowledge to perform the calculation. By providing welding parameters, defining a weld joint, giving geometry dimensions, and specifying a material, weld residual stress and distortion are automatically calculated in a remote high performance computer. A report will then be sent to the engineer to review. This paper introduces the development of E-Weld Predictor. The software structure, the theory, the implementation, and the validation of E-Weld Predictor are discussed in detail. It also shows the simulation process of applying this software in predicting temperature, microstructure, residual stress and distortion.

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