High Performance Computing Tools to Advance Materials Joining Technology

Abstract

In this project, an in-house HPC finite element code was developed with novel computational schemes that provided fast and high-fidelity simulation capability for welding processes and allied manufacturing processes such as metal additive manufacturing processes. Benchmark comparison confirmed that, for the testing cases studied, the newly developed in-house code resulted in increases in computational speed in the ranges of 100x to 1000x depending on the size and complexity of the testing cases, when compared to today’s commercial welding process simulation tools. As demonstrated by the selected examples in this report, the breakthrough increases in computational simulation speeds achieved by the in-house HPC code means that high fidelity simulations of certain complex welding problems that would require months even years of computational time with today’s commercial code could be solved in two to three days. Similar order of magnitudes of reduction in computational times for metal additive manufacturing process were also achieved.