The latest spot weld reliability assurance technology, developed exclusively by Battelle, and adopted for use by Safe Technology’s fe-safe suite of software, is for fatigue analysis from finite element models.

It is a complimentary tool for use with Verity, another Battelle-developed fatigue analysis tool licensed to Safe Technology. The revolutionary Verity mesh insensitive structural stress method uses patented methods to calculate, accurately, the fatigue lives of welded joints by eliminating the uncertainty of traditional methods. 

In the early ’90s, Battelle scientists recognized the need for a reliable stress analysis methodology that would address the known problems encountered in conventional finite element analysis procedures for welded joints and other geometric discontinuities. Consequently, Battelle engineers created, developed, and validated a new methodology known as the Verity mesh-insensitive structural stress methodology. Although initially viewed as "too good to be true" or "too simple to possibly work," Verity has now been validated by leading industry experts across a broad array of industries, and has been adopted by respected codes and standards organizations.

The new spot weld modeling procedure calculates reliable structural stresses consistent with the Verity master S-N curve. As such, there is no requirement for additional fatigue data in order to apply this new approach to wide range of spot welding techniques. Moreover, the new spot weld model is simpler to apply and more computationally efficient, and thus enables greater numbers of spot welds to be analyzed with existing facilities, says Jeong K. Hong, a Battelle technical lead who developed the process.

The fe-safe tool, with spot welding capabilities, can accelerate new product introduction and reduce cost when integrated into the design process. It is primarily being used by the automotive industry and has potential applications everywhere spot welds are used. The fe-safe spot weld module automatically detects the number of sheets welded together, the thickness of each sheet, and the location of each spot weld. Very short analysis times are obtained even with models that contain many thousands of spot welds. The software works with beam elements and with Abaqus connector elements.

“We are pleased to add the new spot welding capability to our Verity suite of fatigue analysis tools. We are continually trying to offer our customers more tools that will help them save time and money in the complex business of fatigue analysis,” states John Draper, Safe Technology’s CEO.