Welding Application


  • CAST-DESIGNER WELD serves as an easy-to-use front end to perform welding assembly simulation for large structures. The physics of welding is fully treated in the same model.
  • The user needs not be familiar with non-linear finite element simulation, only focus on the process design.
  • Thermal cycle, changes in material status, stresses, plastic strains, thermal strains, yield stress of the newly formed material and all other results related to a transient welding simulation are available.

CAST-DESIGNER WELD employs Gantt diagrams to visualize the welding process time. Gantt diagrams visualize the time sequence of process steps as bars on a time axis. It could be used to optimize welding sequences, cooling and clamping and release time.

Different weld sequence caused different distortion result. The left weld sequence (a) bring a maximum 0.58mm distortion while the maximum distortion of the right weld sequence (b) was only 0.32mm.

Friction Stir Welding Simulation

Friction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing work pieces without melting the material. Heat is generated by friction between the rotating tool and the work piece material, which leads to a softened region near the "probe".

CAST-DESIGNER WELD is based on both a thermo-fluid and a thermo-mechanical formulation. The first one is used to model the friction stir welding and the effect of materials stirring on the temperature increased and energy generation. The multiphysics and multiscale coupling with the thermo-mechanical analysis leads to accurate and predictive results in terms of residual distortions, residual stresses and microstructure after FSW. This module has been validated both for aluminum and steel joints.


Effective stress


Stress curve

Spot Welding

Resistance spot welding is an efficient process to join vehicle body parts. This process involves strong interactions between electrical, thermal, metallurgical, and mechanical phenomena.

With the coupling electromagnetism, heat transfer, metallurgy, and mechanics, this process is accurately simulated with CAST-DESIGNER WELD .


The quotation module establishes technical and commercial parameters concerned with the operation of the welding process.

It could be used for the quotation stage for price estimation or the production phase for detail cost control.

Create and compare full costing reports.

The user can customize the currency, process and manpower cost, then calculate the welding cost based on the welding process, manufacture cost, and other operation cost. Finally a multi-language quotation sheet could be generated in Excel file.

CAST-DESIGNER WELD quotation interface and cost report