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In the analysis of welding mechanics, it is difficult to analyze large-scale structures because of welding-specific moving local nonlinearity. In this research, the authors proposed a new numerical method for welding mechanics based on the Dynamic Explicit FEM. In the proposed method, the temperature step is divided into hundreds of time steps as implicit FEM and the displacements are computed for each time step based on dynamic explicit FEM until the whole system reaches the static equilibrium state. And, to achieve the static equilibrium state faster, modified mass and damping matrix are introduced. The modified mass and damping matrix are based on the Courant condition and the vibration theory, respectively. The proposed method and static implicit FEM are compared at the final path of multilayer welding of thick bead-on-plate to verify validity and accuracy. The transient and residual deformation and stress distribution of the proposed method show good agreement with those of static implicit FEM. In addition, the computing time and memory consumption of the proposed method are 1/12 and 1/40 times shorter than those of static implicit FEM, respectively, in 243,243 degree of freedom model. It is found that the proposed method has an advantage in large-scale analysis whose nodal points are more than tens of thousands.

A three-dimensional (3D) deformation (in plane and out of plane deformations) measurement method is developed using digital cameras, which require no special equipment. This method is a non-contact method, and it can sequentially measure over the entire photographed image. Furthermore, since image analysis is based on the technique of image matching, the method is applicable even when the deformation to be measured is large. In addition, since it is possible to use all pixels as measuring points, the number of available measuring points at one time is the same as the number of effective pixels of the camera. In this study, the proposed method is applied to the sequential measurement of displacement under strong lighting levels in arc welding. Through the comparison of the results measured by a 3D shape measurement system (LAT-3D) using a laser displacement gauge and digital caliper, the quantitative validity of the proposed method is also verified.

Due to the rapid improvement of digital cameras, especially the pixel resolution, digital image correlation (DIC) has been introduced to measure the deformation and strain of structures. Using digital cameras for the DIC technique is an easy and fast method for obtaining structural information, represented as all the pixel points in a photo. Because a wide range of structural deformation can be obtained with high accuracy, this method has the potential to be very useful. Currently, DIC can execute a measurement with high accuracy only when the out-of-plane displacement is small. When the out-of-plane displacement is large, the deformation causes the measurement error. Therefore, a stereo imaging method using two digital cameras is proposed in this study. The proposed method can measure not only in-plane deformation but also out-of-plane deformation with high accuracy without calibration of the errors caused by the out-of-plane displacement. In this paper, the measurement accuracy of the proposed method for in-plane deformation and out-of-plane deformation is discussed through the application of a bead-on-plate welding test. The proposed method can measure transverse shrinkage and angular distortion with high accuracy. In contrast to the vernier caliper and laser distance metre measurement methods, which can measure only a few points at a time, the proposed method using two digital cameras can measure the full field in a short time. These results confirm that the proposed method is more advantageous than other methods.

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