From bridges and aircraft to power plants and pipelines, welding holds the world together. But behind every strong weld lies a complex process that can be time-consuming, costly and prone to errors.

At The University of Manchester, researchers are using artificial intelligence to bring welding into the digital age. Their project combines advanced computer simulations with machine learning models that can optimise welding outcomes and spot stresses that could occur during the process.

Instead of relying on trial-and-error, engineers and welders can now explore designs virtually, identifying potential flaws before they happen and ensuring stronger, safer structures over time.

Through the team's approach, what once required hours of detailed simulation or physical testing can now be assessed in moments.

As researcher Zeyuan Miao explains: "By combining advanced simulations with surrogate machine learning models, we automate and accelerate welding process design. Our approach reduces trial-and-error, minimises defects, and shortens development time – bringing intelligent decision-making directly to the welder.

"Welding is everywhere – now we're turning it into smart science. With AI-driven insight, we can help welders worldwide build safer structures, faster and with confidence."