WeldSci is an interactive, browser-based simulator for understanding fusion welding physics and metallurgy. It is intended for welding engineering students, CWI/CWE candidates, fabrication shop technicians, and anyone building process intuition.
Three sliders control the simulation: Arc Voltage (15 to 35 volts), Welding Current (50 to 350 amperes), and Travel Speed (2 to 15 millimetres per second). All values update live. Five preset buttons load named defect scenarios: Optimal Weld, Undercut, Lack of Fusion, Excess Convexity, and Burn Through.
Six computed metrics are displayed: Heat Input Q in joules per millimetre using formula eta times V times I divided by v with efficiency 0.8; Penetration P in millimetres; Leg Length Z in millimetres; Throat Thickness a equal to Z divided by root two; Reinforcement R in millimetres; and Cooling Time t-eight-five in seconds. A diagnosis block states whether the weld is Good or names the defect with two engineering explanations.
Tab one: 45-degree fillet cross-section with annotated leg length, throat, penetration depth, HAZ boundary, weld face, and weld toes. Tab two: Butt weld cross-section with animated build sequence showing the weld bead, penetration zone, HAZ, and any undercut notches, porosity, or solidification crack. Tab three: Bead top-view looking straight down at the weld seam, showing stack-of-dimes blob spacing proportional to travel speed. Tab four: Zone map illustrating concentric metallurgical zones from weld metal outward through fusion zone, coarse-grain HAZ, fine-grain HAZ, to base metal. Tab five: Thermal profile chart plotting time-temperature curves for three radial positions — weld centre, fusion line, and HAZ at five millimetres — with liquidus and solidus phase lines and t-eight-five cooling interval marked.
The second navigation tab lists six engineering equations with acceptable ranges and reject criteria: Heat Input, Bead Aspect Ratio, Empirical Penetration, Carbon Equivalent, Throat Thickness, and Residual Stress.
AWS D1.1 Structural Welding Code for Steel. ISO 5817 Welding Quality Levels for Imperfections. EN 1993-1-8 Eurocode 3 Design of Joints.
For instructional use only. Follow applicable WPS and PQR for production welding work.
Machine-readable documentation available at /llms.txt.