Hi Saransh,

I do not have experience of Ansys for this application, but I have used Abaqus for modelling of welding. The error mentions that "an internal solution magnitude limit was exceeded". Is it possible that you have set a limit to the allowable change in temperature per increment, and that the actual change in the time step is too large? If yes, you could decrease the minimum time step size.

Regards,

Simon

Hi Sir, Simon Smith

I tried decreasing the minimum time step size and even tried program controlled auto time stepping but the error stays

The error in solution information says

*** ERROR ***                           CP =      10.297   TIME= 17:23:44  The value of TEMP at node 2466 is 9199670.69.  It is greater than the    current limit of 1000000 (which can be reset on the NCNV command).       This generally indicates that there are no temperature constraints or    convections applied

Regards

Saransh

Hi Saransh,

That's a v high temperature! What sort of welding heat source are you using?

Regards,

Simon

Simon Smith

I am using a moving heat flux with velocity 8 mm/s, radius of beam as 4 mm and source power intensity as 31.83 W/mm2

Simulating TIG welding in ANSYS can be challenging! I'd be happy to help you troubleshoot. To better understand your issue, can you please provide more details about: 1. _Error message_: What is the exact error message you're getting? 2. _ANSYS version_: Which version of ANSYS are you using? 3. _Model setup_: Can you describe your model setup, including: - Geometry (e.g., pipe, plate, or 3D part)? - Mesh type and size? - Material properties? - Heat source definition (e.g., moving heat source, Gaussian distribution)? - Thermal boundary conditions (e.g., convection, radiation)? 4. _Element birth and death method_: How have you implemented this method in your simulation? 5. _Moving heat source_: How are you defining the movement of the heat source along the circumference? Once I have more information, I can provide more specific guidance to help you resolve the issue.j

Hi Sir, Bitrus Pius Ekpo

1. The value of TEMP at node 2466 is 9199670.69.  It is greater than the    current limit of 1000000 (which can be reset on the NCNV command).       This generally indicates that there are no temperature constraints or    convections applied

2. I am using Ansys version 2023

I have attached a PDF file for other information

Regards

Saransh

It looks like you're encountering a temperature limit error in Ansys 2023.

The error message indicates that:

1. The temperature at node 2466 (TEMP = 9199670.69) exceeds the default temperature limit of 1,000,000.

2. This might be due to the lack of temperature constraints or convection applied to the model.

To resolve this issue, consider the following:

1. *Apply temperature constraints*: Ensure that you have applied appropriate temperature constraints, such as fixed temperatures or temperature-dependent boundary conditions.

2. *Add convection*: Include convection boundary conditions to simulate heat transfer between the model and the surrounding environment.

3. *Check material properties*: Verify that the material properties, such as thermal conductivity, specific heat capacity, and density, are accurate and consistent.

4. *Mesh refinement*: Refine the mesh in areas with high temperature gradients to improve the accuracy of the results.

5. *Reset temperature limit*: If you're confident that the high temperature is physically realistic, you can reset the temperature limit using the NCNV command.

Before making any changes, save a copy of your current model to avoid losing any progress.

If you're still unsure or encounter further issues, feel free to provide more details about your model, and I'll do my best to assist you!

Bitrus Pius Ekpo

Sir I tried rechecking everything

but the error stays

Okay let me take another way

Let's try to troubleshoot further. Can you please provide more details about your simulation setup: 1. What type of analysis are you running (e.g., steady-state, transient, thermal)? 2. What are your boundary conditions (e.g., temperature, heat flux, convection)? 3. What materials are you using, and have you checked their thermal properties? 4. Have you applied any mesh controls or refinements? 5. Are there any other warnings or errors in the ANSYS output? Additionally, you can try: 1. Checking the ANSYS documentation for specific guidance on temperature limits. 2. Searching online forums or communities for similar issues. 3. Reaching out to ANSYS support or consulting with an expert. Let's work together to resolve this issue!