Solution to the problem is to apply face mesh to cross section which is a easy solution for me.


Thanks for sharing your experience. My project is an academic research project and I have to bear to welding specification as per AWS. On the top of it, mesh convergence study becomes more representable with sweep mesh. I certainly agree that Spaceclaim can produce tight tolerances however there are some modelling features that I could not find in SC which is available in SolidWorks ( probably because of my lack of experience in SC). This is not one off model but around 50 models and much more complext than this configuration. So I prefer to stick to the software that I am competent with given that I have sort time frame. I actually gave up splitting body around weld toes which eliminated all problems