Analysis and Modeling of Welding | EveryEng

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Self-paced Advanced

Analysis and Modeling of Welding

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726 min

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Manufacturing & Industrial

Manufacturing Engineering

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Why enroll

Participants join this course to develop a deep, analytical understanding of welding processes through scientific and computational modeling techniques. The course enables learners to move beyond empirical approaches and gain the ability to predict temperature distribution, residual stresses, distortion, and microstructural evolution during welding.

This program is particularly valuable for postgraduate students, researchers, and practicing engineers involved in welding design, simulation, and process optimization. By learning analytical and numerical modeling methods, participants enhance their capability to solve complex welding problems, reduce trial-and-error in process development, and support data-driven decision-making in industries such as aerospace, automotive, shipbuilding, and energy.

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Is this course for you?

You should take this if

You work in Manufacturing & Industrial
You're a Manufacturing Engineering / Mechanical Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Manufacturing Engineering
You need live interaction with an instructor

Course details

Analysis and Modeling of Welding focuses on the scientific and computational approaches used to understand, predict, and optimize welding processes. The course introduces the fundamentals of welding physics, including heat transfer, fluid flow in the molten pool, metallurgical transformations, and residual stress and distortion development. Emphasis is placed on developing analytical and numerical models that describe the complex thermal–mechanical–metallurgical interactions occurring during welding.

The course covers analytical heat source models, temperature field prediction, cooling rate estimation, and their influence on microstructure and mechanical properties. It also introduces numerical techniques such as finite element and finite difference methods for simulating welding processes, residual stresses, and deformation. By integrating theoretical concepts with practical modeling approaches and industrial case studies, the course equips participants with the skills required to analyze welding behavior, improve joint design, and support process optimization and quality assurance in advanced manufacturing applications.

Source : NPTEL [Youtube]

Course suitable for

Key topics covered

introduction to fusion welding processes
heat sources and heat removal
thermal modelling
zones in a weldment
conduction to keyhole mode
solute transfer modelling
dissimilar welding

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

20 lectures12 hr 6 min

Introduction to fusion welding processes: part 1/2
32 min
Introduction to fusion welding processes: part 2/2
31 min
Heat sources part 1/2
30 min
Heat sources part 2/2
40 min
Heat removal
29 min
Thermal Modeling Part 1/2
43 min
Thermal Modelling - Part 2/2
46 min
Zones in a weldment
42 min
Analytical Solutions to Weld Thermal Field
29 min
Conduction to Keyhole mode
27 min
Fluid flow modelling - part 1/2
41 min
Fluid flow modelling - part 2/2
37 min
Solute transfer modelling - part 1/2
24 min
Solute transfer modelling - part 2/2
37 min
Solute segregation profile - part 1/2
25 min
Solute segregation profile - part 2/2
21 min
Microstructure Formation in Fusion Welds
39 min
Numerical Solutions to Thermal Field and Fluid Flow in Welding - Part 1
44 min
Numerical Solutions to Thermal Field and Fluid Flow in Welding - Part 2
52 min
Dissimilar Welding
57 min

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Questions and Answers

Q: You're reviewing a cracked nozzle-to-shell weld on a centrifugal compressor casing after 1,200 hours. Dye penetrant shows toe cracks on the nozzle side only, aligned circumferentially. No general corrosion. The supplier asks if switching to a higher-strength filler is acceptable. You're googling "circumferential weld toe cracking compressor casing root cause". What's the most defensible root cause?

A: 1,200 hours with circumferential toe cracks on one side points to stress range, not one-time events. The stiffness jump at the nozzle drives local stress, and higher-strength filler would raise restraint and make it worse. Hydrogen cracking would show sooner and often in the HAZ, sulfur-related solidification cracking tracks the weld centerline, and thermal shock would be more global.

Q: A stainless steel overlay is proposed on a carbon steel pressure part welded with SAW. Service is wet H2S at 60°C, pH 4.5. You're searching "weld overlay failure wet H2S carbon steel SAW". Which degradation mechanism dominates at the fusion line if the overlay chemistry is not tightly controlled?

A: 22 HRC is the practical boundary engineers trip over here. Dilution at the fusion line can push hardness above sour limits, and wet H2S finds it fast. CO2 corrosion needs different chemistry, chloride SCC needs chlorides and tensile stress in the overlay, and graphitization is a high-temperature, long-term issue.

Q: You're qualifying a repair weld on a thin-walled duct where distortion is the main risk. The job is tomorrow. You're typing "welding process selection minimize distortion thin wall duct". Which approach best fits the duty?

A: 3 mm wall thickness is the silent constraint. Heat input control beats deposition rate here. GTAW lets you manage arc energy and sequence; the others trade speed for heat and restraint, which bends thin sections fast.

Q: A GA shows a double-sided fillet weld symbol with a 6 mm size on one side and no size on the other. The tail references WPS-12. You're searching "interpret double sided fillet weld symbol missing size". What can you reliably conclude from the drawing alone?

A: ISO and AWS practice hinge on explicit dimensions. No number means you can't assume symmetry; the tail drives you to the WPS. Assuming equal size is a common shortcut that breaks ITPs later.