Case Study: Rolls‑Royce achieves accurate prediction of weld distortion and residual stresses with Dassault Systèmes' Abaqus Welding Interface (SIMULIA)

Rolls-Royce uses Abaqus 2D weld simulation tool to model complex metal fabrication processes

Rolls‑Royce’s Marine division needed to better predict the complex thermal and structural effects of welding—distortion during manufacture, peak residual stresses, and material behavior under multi‑pass welds—to improve design, manufacturing and welder/robot training. To address this, Rolls‑Royce evaluated several FEA tools and adopted the Abaqus Welding Interface (AWI) and Abaqus/CAE from Dassault Systemes (SIMULIA) to extend their weld‑analysis capabilities.

Using Dassault Systemes’ Abaqus Welding Interface, Rolls‑Royce built 2D weld models (autogenous, eight‑pass groove and seven‑pass ring welds), automated weld bead and surface heat‑transfer definitions, and coupled thermal results into structural analyses within Abaqus/CAE. The AWI sped model setup, reduced data translation issues and training effort, and produced validated results—neutron diffraction measurements showed a particularly close correlation with the one‑pass FEA—while ongoing work refines multi‑pass accuracy.

Rolls-Royce

David Hodgson

Stress Engineer