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Combinatorial optimization of weld sequence by using a surrogate model to mitigate a weld distortion

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Abstract

Choosing an optimal sequence from the set of all possible combinations of a weld’s sub-passes is always a challenge for designers. The solution of such combinatorial optimization problems is limited by the available resources. For example, having n sub-passes leads to choosing from 2n × n! possible combinations of the sub-passes, e.g., 46,080 for n = 6. It is not feasible to choose the optimal sequence by evaluating all possible combinations either experimentally or by simulation models. The purpose of using a surrogate model based on a simulation model is to find the solution in the space of all possible combinations with a significant decrease in computational expenses. In effect, the surrogate model constructs an approximation model from some combinations of solutions of a more expensive model to mimic the behavior of the simulation model as closely as possible but at a much lower computational cost. This surrogate model, then, could be used to approximate the behavior of the other combinations. In this paper, a surrogate model is demonstrated that minimizes the distortion in a pipe girth weld with six sub-passes by analyzing only 14 combinations of sub-passes from total of 48 possible combinations. A comparison between the results of the surrogate model and the full transient FEM analysis all possible combinations shows the accuracy of the algorithm/model.

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Acknowledgements

The authors wish to acknowledge technical supports from Daniel Downy, Stainslav Tchernov and Jianguo Zhou from Goldak Technologies Inc.

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, Carleton University, 1125 CBY, Ottawa, ON, K1S 5B6, Canada

    Mahyar Asadi & John A. Goldak

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  1. Mahyar Asadi
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  2. John A. Goldak
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Correspondence to Mahyar Asadi.

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Asadi, M., Goldak, J.A. Combinatorial optimization of weld sequence by using a surrogate model to mitigate a weld distortion. Int J Mech Mater Des 7, 123–139 (2011). https://doi.org/10.1007/s10999-011-9154-6

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  • DOI: https://doi.org/10.1007/s10999-011-9154-6

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