I have been pushing up the size of shell weldments in terms of quantity of parts, and have been running into more and more issues with the bond connection not working.  Should the "global bonded" connections be automatic for any two shells that are contacting edges?  I have given up on that and am mostly defining the bonds one pair at a time but even then see a lot of failures unless they are perfectly connected (no gap at all and identical length edges).  The worst part of this issue is that a failed bond does not give an error during the mesh which makes it very hard to troubleshoot.

Does anyone have some suggestions or can send me to a guide on how to best set up and bond shell elements for larger studies?

Thanks

Bruce