Enhancing Welding Geometric Precision: Analyzing the Impact of Weld Path Directions, Sequences and Locating Schemes on Displacement

Welding-induced geometric deviations remain a critical challenge in industrial manufacturing, particularly in achieving high-precision assembly. This study investigates the effects of welding path directions, sequences, and locating schemes on the displacement of welded assemblies, focusing on minimizing geometric deviations. Using finite element method (FEM) simulations and a design of experiments (DOE) approach, the interactions between these parameters were systematically analyzed. Results show that the locating scheme plays a dominant role in controlling displacement, with optimal configurations significantly reducing geometric errors. Welding sequences were also found to have a considerable impact, further minimizing distortions when appropriately optimized. The effect of weld path direction, while less significant for simpler geometries, became more pronounced in assemblies with curvature. These findings pinpoint the necessity of integrating a combined factor approach, including fixturing, welding sequence, and path direction, to optimize and improve the geometric quality of welded assemblies.