This paper presents an effective numerical approach for welding process
parameter optimization to minimize weld-induced distortion in
structures. A numerical optimization framework based on coupled Genetic
Algorithm (GA) and Finite Element Analysis (FEA) is developed and
implemented for a low and a high fidelity model. Classical weakly
coupled thermo-mechanical analysis with thermo-elasto-plastic
assumptions is carried out for distortion prediction of numerical
models. The search for optimum process parameters is executed by direct
integration of numerical models and GA-based optimization technique. The
developed framework automatically inserts the process parameters into
the simulation models, executes the FE-based welding simulations and
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