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Using high power computing platforms for simulation and weld modeling enables welding engineers to explore complex welding and weld design parameters. This paper presents the authors’ experience in delivering advanced welding modeling and simulation services to industrial clients. The main theme of this paper is that practical solutions will be found if a service provider becomes skillful in handling significantly large number of modeling analyses in a short time frame. This paper presents industrial projects where this approach helped clients to define an optimal design envelope with a clear understanding of the correlation between large number of design parameters – an understanding that is not possible to achieve through analytical approaches, and unfeasible through experimentation alone. As presented here, modeling and simulation analyses can be the only feasible approach to developing engineering solutions for many complex problems.