Abstract
This case study presents an example of virtual design in relation to overlay welding for maintenance of a diecasting mold. Two departments were involved in the overlay welding process. Virtual design was used to evaluate the understanding of the welding conditions by the workers in both departments. This led to the isolation of factors with a major effect on overlay welding, but the two departments took diametrically opposite views of the effect of one of the factors. Test pieces that both departments thought would be affected by this factor were made by the two departments and evaluated in terms of electric power consumption during the welding process. Quality of the test pieces was also evaluated by a tension test. The results indicated which factor level was superior, and were shown to both departments. Evaluation by virtual design and functional testing thus led to a better understanding of the welding skills in the two departments.
