formulab 0.16.0 → 0.20.0

package/dist/math.d.ts

@@ -19,8 +19,4 @@ export declare function normalCDF(x: number): number;
  * @returns z-score such that P(Z ≤ z) = p
  */
 export declare function normalInvCDF(p: number): number;
-/**
- * Clamp a value to a range [min, max].
- */
-export declare function clamp(value: number, min: number, max: number): number;
 //# sourceMappingURL=math.d.ts.map

package/dist/math.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"math.d.ts","sourceRoot":"","sources":["../src/math.ts"],"names":[],"mappings":"AAAA;;;;;GAKG;AAEH;;;;;GAKG;AACH,wBAAgB,SAAS,CAAC,CAAC,EAAE,MAAM,GAAG,MAAM,CAe3C;AAED;;;;;;GAMG;AACH,wBAAgB,YAAY,CAAC,CAAC,EAAE,MAAM,GAAG,MAAM,CAsD9C"}

package/dist/math.js

@@ -86,10 +86,4 @@ export function normalInvCDF(p) {
             ((((d[0] * q + d[1]) * q + d[2]) * q + d[3]) * q + 1);
     }
 }
-/**
- * Clamp a value to a range [min, max].
- */
-export function clamp(value, min, max) {
-    return Math.max(min, Math.min(max, value));
-}
 //# sourceMappingURL=math.js.map

package/dist/math.js.map

@@ -1 +1 @@
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package/dist/metal/hardness.d.ts

@@ -9,6 +9,11 @@ export declare const CONVERSION_TABLE: ConversionRow[];
 /**
  * Convert a hardness value from one scale to all scales using
  * linear interpolation on the conversion table.
+ *
+ * Inputs outside the table (e.g. HRC below 20 or above 68) are clamped to the boundary
+ * row and disclosed via `outOfTableRange: true` — the returned values are then a boundary
+ * approximation, not a conversion of the input. Exact boundary hits are table hits and
+ * are not flagged. Interpolation within the table is the method's intended behavior.
  */
 export declare function hardness(input: HardnessInput): HardnessResult;
 export {};

package/dist/metal/hardness.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"hardness.d.ts","sourceRoot":"","sources":["../../src/metal/hardness.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAiB,aAAa,EAAE,cAAc,EAAE,MAAM,YAAY,CAAC;AAE/E,UAAU,aAAa;IACrB,GAAG,EAAE,MAAM,CAAC;IACZ,EAAE,EAAE,MAAM,CAAC;IACX,EAAE,EAAE,MAAM,CAAC;IACX,KAAK,EAAE,MAAM,CAAC;CACf;AAID,eAAO,MAAM,gBAAgB,EAAE,aAAa,EAY3C,CAAC;AAoBF;;;;;;;;GAQG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CAmD7D"}

package/dist/metal/hardness.js

@@ -29,29 +29,38 @@ function interpolate(scale, value, low, high) {
 /**
  * Convert a hardness value from one scale to all scales using
  * linear interpolation on the conversion table.
+ *
+ * Inputs outside the table (e.g. HRC below 20 or above 68) are clamped to the boundary
+ * row and disclosed via `outOfTableRange: true` — the returned values are then a boundary
+ * approximation, not a conversion of the input. Exact boundary hits are table hits and
+ * are not flagged. Interpolation within the table is the method's intended behavior.
  */
 export function hardness(input) {
     const { fromScale, value } = input;
     // Sort table by the source scale ascending
     const sorted = [...CONVERSION_TABLE].sort((a, b) => a[fromScale] - b[fromScale]);
+    const min = sorted[0][fromScale];
+    const max = sorted[sorted.length - 1][fromScale];
     // Clamp: if value is at or below the minimum row
-    if (value <= sorted[0][fromScale]) {
+    if (value <= min) {
         const row = sorted[0];
         return {
             HRC: row.HRC,
             HB: row.HB,
             HV: row.HV,
             Shore: row.Shore,
+            outOfTableRange: value < min,
         };
     }
     // Clamp: if value is at or above the maximum row
-    if (value >= sorted[sorted.length - 1][fromScale]) {
+    if (value >= max) {
         const row = sorted[sorted.length - 1];
         return {
             HRC: row.HRC,
             HB: row.HB,
             HV: row.HV,
             Shore: row.Shore,
+            outOfTableRange: value > max,
         };
     }
     // Find the two bracketing rows
@@ -59,7 +68,7 @@ export function hardness(input) {
         const low = sorted[i];
         const high = sorted[i + 1];
         if (value >= low[fromScale] && value <= high[fromScale]) {
-            return interpolate(fromScale, value, low, high);
+            return { ...interpolate(fromScale, value, low, high), outOfTableRange: false };
         }
     }
     // Fallback (should not reach here)
@@ -69,6 +78,7 @@ export function hardness(input) {
         HB: row.HB,
         HV: row.HV,
         Shore: row.Shore,
+        outOfTableRange: false,
     };
 }
 //# sourceMappingURL=hardness.js.map

package/dist/metal/hardness.js.map

@@ -1 +1 @@
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package/dist/metal/roughness.d.ts

@@ -2,6 +2,13 @@ import type { RoughnessInput, RoughnessResult } from './types.js';
 /**
  * Convert surface roughness between Ra, Rz, and N class.
  *
+ * Conversion is a lookup against the ISO 1302 grade table (N1-N12, Ra 0.025-50 µm,
+ * Rz 0.1-200 µm) with nearest-grade snapping. Inputs outside the table — realistic ones exist
+ * on both ends (lapped/superfinished Ra ≈ 0.006 µm, rough sand casting Ra ≈ 100 µm) — are
+ * snapped to the boundary grade and disclosed via `outOfTableRange: true`, because the
+ * returned grade is then NOT equivalent to the input (up to 4× off at the edges).
+ *
+ * @reference ISO 1302 — surface texture indication, N-grade table
  * @throws RangeError if value is not positive
  */
 export declare function roughness(input: RoughnessInput): RoughnessResult;

package/dist/metal/roughness.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"roughness.d.ts","sourceRoot":"","sources":["../../src/metal/roughness.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,cAAc,EAAE,eAAe,EAAE,MAAM,YAAY,CAAC;AA8BlE;;;;;;;;;;;GAWG;AACH,wBAAgB,SAAS,CAAC,KAAK,EAAE,cAAc,GAAG,eAAe,CAoChE"}

package/dist/metal/roughness.js

@@ -28,6 +28,13 @@ function findClosest(key, value) {
 /**
  * Convert surface roughness between Ra, Rz, and N class.
  *
+ * Conversion is a lookup against the ISO 1302 grade table (N1-N12, Ra 0.025-50 µm,
+ * Rz 0.1-200 µm) with nearest-grade snapping. Inputs outside the table — realistic ones exist
+ * on both ends (lapped/superfinished Ra ≈ 0.006 µm, rough sand casting Ra ≈ 100 µm) — are
+ * snapped to the boundary grade and disclosed via `outOfTableRange: true`, because the
+ * returned grade is then NOT equivalent to the input (up to 4× off at the edges).
+ *
+ * @reference ISO 1302 — surface texture indication, N-grade table
  * @throws RangeError if value is not positive
  */
 export function roughness(input) {
@@ -35,27 +42,34 @@ export function roughness(input) {
     if (value <= 0) {
         throw new RangeError('value must be greater than 0');
     }
+    const first = ISO_1302_TABLE[0];
+    const last = ISO_1302_TABLE[ISO_1302_TABLE.length - 1];
     let entry;
+    let outOfTableRange = false;
     if (fromScale === 'N') {
         const n = roundTo(value, 0);
         entry = ISO_1302_TABLE.find(e => e.n === n);
         if (!entry) {
-            // clamp to valid range
+            // outside N1-N12 — snap to the boundary grade and disclose
+            outOfTableRange = true;
             const clamped = Math.max(1, Math.min(12, n));
             entry = ISO_1302_TABLE.find(e => e.n === clamped);
         }
     }
     else if (fromScale === 'Ra') {
         entry = findClosest('ra', value);
+        outOfTableRange = value < first.ra || value > last.ra;
     }
     else {
         entry = findClosest('rz', value);
+        outOfTableRange = value < first.rz || value > last.rz;
     }
     return {
         ra: roundTo(entry.ra, 3),
         rz: roundTo(entry.rz, 1),
         nClass: entry.n,
         rms: roundTo(entry.ra * 1.11, 3),
+        outOfTableRange,
     };
 }
 //# sourceMappingURL=roughness.js.map

package/dist/metal/roughness.js.map

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package/dist/metal/springback.d.ts

@@ -8,21 +8,45 @@ import type { SpringbackInput, SpringbackResult } from './types.js';
  * grows with the R/t ratio and with the yield-strength-to-stiffness ratio Y/E —
  * which is why aluminium springs back far more than steel at the same geometry.
  *
- * @formula x  = Y · R_i / (E · T)                (dimensionless)
- * @formula Ks = R_i / R_f = 4x³ − 3x + 1         (springback factor, ≤ 1)
+ * @formula x  = Y · R_i / (E · T)                (dimensionless, model domain x < 0.5)
+ * @formula Ks = R_i / R_f = 4x³ − 3x + 1         (springback factor, 0 < Ks ≤ 1 on the domain)
  * @formula R_f = R_i / Ks · θ_final = θ_tool · Ks ⇒ θ_overbend = θ_target / Ks
  * @reference Kalpakjian & Schmid, "Manufacturing Engineering and Technology",
  *            springback equation for pure bending (also in ASM Metals Handbook
  *            Vol. 14B, Sheet Forming). Valid for R_i > 2T, where the neutral axis
  *            sits at mid-thickness; θ scales with Ks because the neutral-axis arc
  *            length is conserved through unloading.
+ *
+ *            Model domain: the cubic factors as Ks = (x + 1)(2x − 1)², a double root
+ *            at x = 0.5 — which is exactly the elastic limit: x ≥ 0.5 ⇔ the maximum
+ *            bending strain T/2R_i stays at or below the yield strain Y/E, so the
+ *            sheet never yields and springs back completely (no permanent set).
+ *            Past the root the polynomial climbs again (x = 1 → Ks = 2, i.e. negative
+ *            springback), which is a mathematical artifact with no physical meaning,
+ *            so inputs with x ≥ 0.5 are rejected rather than evaluated (ISSUE-20260714:
+ *            the unguarded cubic returned Infinity at x = 0.5 and shrinking radii beyond).
  * @units thickness/bendRadius mm · bendAngle degrees · yieldStrength MPa · elasticModulus GPa
  * @validation thickness > 0, bendRadius > 0, 0 < bendAngle < 180; for material
- *             'custom', yieldStrength > 0 and elasticModulus > 0 are required.
+ *             'custom', yieldStrength > 0 and elasticModulus > 0 are required;
+ *             x = Y·R_i/(E·T) < 0.5 (below the elastic limit, see @reference).
+ * Even inside the domain the required overbend can pass 180° (thin sheet, large radius,
+ * target angle near 180°) — a valid model prediction that no single press-brake stroke
+ * can execute. The result discloses this via `overbendExceeds180` instead of throwing:
+ * the number itself still tells the fabricator the part cannot be made in one hit.
+ *
+ * Tight bends (R_i ≤ 2T) are common in practice but sit below the model's stated
+ * validity (the neutral axis shifts off mid-thickness), so rather than rejecting them
+ * the result discloses the accuracy caveat via `radiusBelow2T`.
+ *
  * @param input - Geometry plus material (preset or custom Y/E)
- * @returns Springback factor, final radius, springback angle, and overbend angle
+ * @returns Springback factor, final radius, springback angle, overbend angle, and
+ *          disclosure flags: `overbendExceeds180` when the overbend is not achievable
+ *          in a single bend, `radiusBelow2T` when the geometry is below the model's
+ *          stated validity (R_i > 2T)
  * @throws {RangeError} thickness, bendRadius or bendAngle out of range
  * @throws {RangeError} material is 'custom' but yieldStrength/elasticModulus missing or non-positive
+ * @throws {RangeError} x = Y·R_i/(E·T) ≥ 0.5 — the bend stays fully elastic (no permanent
+ *                      set), outside the springback model's domain
  */
 export declare function springback(input: SpringbackInput): SpringbackResult;
 //# sourceMappingURL=springback.d.ts.map

package/dist/metal/springback.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"springback.d.ts","sourceRoot":"","sources":["../../src/metal/springback.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,eAAe,EAAE,gBAAgB,EAAmB,MAAM,YAAY,CAAC;AAcrF;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;GAgDG;AACH,wBAAgB,UAAU,CAAC,KAAK,EAAE,eAAe,GAAG,gBAAgB,CA8DnE"}

package/dist/metal/springback.js

@@ -19,21 +19,45 @@ const MATERIAL_PROPS = {
  * grows with the R/t ratio and with the yield-strength-to-stiffness ratio Y/E —
  * which is why aluminium springs back far more than steel at the same geometry.
  *
- * @formula x  = Y · R_i / (E · T)                (dimensionless)
- * @formula Ks = R_i / R_f = 4x³ − 3x + 1         (springback factor, ≤ 1)
+ * @formula x  = Y · R_i / (E · T)                (dimensionless, model domain x < 0.5)
+ * @formula Ks = R_i / R_f = 4x³ − 3x + 1         (springback factor, 0 < Ks ≤ 1 on the domain)
  * @formula R_f = R_i / Ks · θ_final = θ_tool · Ks ⇒ θ_overbend = θ_target / Ks
  * @reference Kalpakjian & Schmid, "Manufacturing Engineering and Technology",
  *            springback equation for pure bending (also in ASM Metals Handbook
  *            Vol. 14B, Sheet Forming). Valid for R_i > 2T, where the neutral axis
  *            sits at mid-thickness; θ scales with Ks because the neutral-axis arc
  *            length is conserved through unloading.
+ *
+ *            Model domain: the cubic factors as Ks = (x + 1)(2x − 1)², a double root
+ *            at x = 0.5 — which is exactly the elastic limit: x ≥ 0.5 ⇔ the maximum
+ *            bending strain T/2R_i stays at or below the yield strain Y/E, so the
+ *            sheet never yields and springs back completely (no permanent set).
+ *            Past the root the polynomial climbs again (x = 1 → Ks = 2, i.e. negative
+ *            springback), which is a mathematical artifact with no physical meaning,
+ *            so inputs with x ≥ 0.5 are rejected rather than evaluated (ISSUE-20260714:
+ *            the unguarded cubic returned Infinity at x = 0.5 and shrinking radii beyond).
  * @units thickness/bendRadius mm · bendAngle degrees · yieldStrength MPa · elasticModulus GPa
  * @validation thickness > 0, bendRadius > 0, 0 < bendAngle < 180; for material
- *             'custom', yieldStrength > 0 and elasticModulus > 0 are required.
+ *             'custom', yieldStrength > 0 and elasticModulus > 0 are required;
+ *             x = Y·R_i/(E·T) < 0.5 (below the elastic limit, see @reference).
+ * Even inside the domain the required overbend can pass 180° (thin sheet, large radius,
+ * target angle near 180°) — a valid model prediction that no single press-brake stroke
+ * can execute. The result discloses this via `overbendExceeds180` instead of throwing:
+ * the number itself still tells the fabricator the part cannot be made in one hit.
+ *
+ * Tight bends (R_i ≤ 2T) are common in practice but sit below the model's stated
+ * validity (the neutral axis shifts off mid-thickness), so rather than rejecting them
+ * the result discloses the accuracy caveat via `radiusBelow2T`.
+ *
  * @param input - Geometry plus material (preset or custom Y/E)
- * @returns Springback factor, final radius, springback angle, and overbend angle
+ * @returns Springback factor, final radius, springback angle, overbend angle, and
+ *          disclosure flags: `overbendExceeds180` when the overbend is not achievable
+ *          in a single bend, `radiusBelow2T` when the geometry is below the model's
+ *          stated validity (R_i > 2T)
  * @throws {RangeError} thickness, bendRadius or bendAngle out of range
  * @throws {RangeError} material is 'custom' but yieldStrength/elasticModulus missing or non-positive
+ * @throws {RangeError} x = Y·R_i/(E·T) ≥ 0.5 — the bend stays fully elastic (no permanent
+ *                      set), outside the springback model's domain
  */
 export function springback(input) {
     const { thickness, bendRadius, bendAngle, material = 'mildSteel' } = input;
@@ -64,6 +88,13 @@ export function springback(input) {
     // Y is MPa and E is GPa — convert E so x stays dimensionless.
     const eMPa = elasticModulus * 1000;
     const x = (yieldStrength * bendRadius) / (eMPa * thickness);
+    // x ≥ 0.5 ⇔ max bending strain T/2R_i ≤ yield strain Y/E: the sheet never yields,
+    // springs back completely, and the cubic below leaves its physical branch (double
+    // root at x = 0.5, then Ks > 1 ⇒ negative springback). See @reference.
+    if (x >= 0.5) {
+        throw new RangeError(`bend stays fully elastic (x = Y*R/(E*T) = ${x.toFixed(4)} >= 0.5): the sheet takes no ` +
+            'permanent set at this radius/thickness/material, outside the springback model domain (x < 0.5)');
+    }
     const springbackFactor = 4 * x ** 3 - 3 * x + 1;
     const finalRadius = bendRadius / springbackFactor;
     const overbendAngle = bendAngle / springbackFactor;
@@ -73,6 +104,12 @@ export function springback(input) {
         finalRadius: roundTo(finalRadius, 2),
         springbackAngle: roundTo(springbackAngle, 2),
         overbendAngle: roundTo(overbendAngle, 2),
+        // Compared before rounding: a bend needs a tool angle < 180° (same bound the target
+        // angle is validated against), so ≥ 180° means "not reachable in a single bend".
+        overbendExceeds180: overbendAngle >= 180,
+        // The @reference validity is R_i > 2T (neutral axis at mid-thickness), so equality
+        // is already outside it. Tight bends are routine — disclose, don't reject.
+        radiusBelow2T: bendRadius <= 2 * thickness,
         yieldStrength,
         elasticModulus,
     };

package/dist/metal/springback.js.map

@@ -1 +1 @@
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package/dist/metal/types.d.ts

@@ -63,6 +63,8 @@ export interface SpringbackResult {
     finalRadius: number;
     springbackAngle: number;
     overbendAngle: number;
+    overbendExceeds180: boolean;
+    radiusBelow2T: boolean;
     yieldStrength: number;
     elasticModulus: number;
 }
@@ -262,6 +264,7 @@ export interface HardnessResult {
     HB: number;
     HV: number;
     Shore: number;
+    outOfTableRange: boolean;
 }
 /**
  * Material Types
@@ -328,6 +331,7 @@ export interface RoughnessResult {
     rz: number;
     nClass: number;
     rms: number;
+    outOfTableRange: boolean;
 }
 /**
  * Screw Types
@@ -485,7 +489,7 @@ export type WeldPreheatSourceCode = 'awsTable' | 'awsJudgment' | 'engineeringJud
  * corresponding English sentence in `recommendations`, allowing consumers to
  * localise the advice while interpolating the supplied `params`.
  */
-export type WeldRecommendationCode = 'preheat' | 'fastCooling' | 'slowCooling' | 'increaseHeatInput' | 'highHeatInput' | 'lowHydrogenConsumables' | 'keepConsumablesDry' | 'pwht' | 'highHazHardness' | 'stainlessInterpass' | 'stainlessFiller' | 'castIronNiFiller' | 'castIronPeen' | 'castIronButter';
+export type WeldRecommendationCode = 'preheat' | 'fastCooling' | 'slowCooling' | 'increaseHeatInput' | 'highHeatInput' | 'lowHydrogenConsumables' | 'keepConsumablesDry' | 'pwht' | 'highHazHardness' | 'hazHardnessCapped' | 'stainlessInterpass' | 'stainlessFiller' | 'castIronNiFiller' | 'castIronPeen' | 'castIronButter';
 /**
  * Machine-readable form of a single recommendation: a stable `code` plus the
  * interpolation `params` used in the matching English `recommendations` string.
@@ -516,6 +520,7 @@ export interface WeldHeatResult {
     carbonEquivalent: number;
     carbonEquivalentPcm: number;
     coolingTime_t85: number;
+    coolingTimeClamped: boolean;
     coolingRate: number;
     preheatTemp: {
         min: number;
@@ -528,6 +533,7 @@ export interface WeldHeatResult {
         max: number;
     };
     hazHardnessMax: number;
+    hazHardnessClamped: boolean;
     crackingRisk: CrackingRisk;
     hydrogenLevel: 'low' | 'medium' | 'high';
     /** Human-readable English advice. */

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package/dist/metal/weldHeat.d.ts

@@ -7,6 +7,11 @@ import type { WeldHeatInput, WeldHeatResult } from './types.js';
  * sentences) and `recommendationCodes` (stable `{ code, params }` entries for
  * i18n). `preheatTemp.source` likewise has a stable `preheatTemp.sourceCode`.
  *
+ * Both `coolingTime_t85` (model range 0.5-300 s) and `hazHardnessMax` (150-700 HV) are
+ * clamped to their models' validity ranges; when that happens `coolingTimeClamped` /
+ * `hazHardnessClamped` is set and the reported number is a boundary value, not a prediction
+ * (at the 700 HV ceiling it is a lower bound — stainless and cast iron compositions hit it).
+ *
  * @throws {RangeError} voltage, current, travelSpeed, or thickness is not positive
  */
 export declare function weldHeat(input: WeldHeatInput): WeldHeatResult;

package/dist/metal/weldHeat.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EACV,aAAa,EACb,cAAc,EAMf,MAAM,YAAY,CAAC;AA2KpB;;;;;;;;;GASG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CAkJ7D"}
+{"version":3,"file":"weldHeat.d.ts","sourceRoot":"","sources":["../../src/metal/weldHeat.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EACV,aAAa,EACb,cAAc,EAMf,MAAM,YAAY,CAAC;AAoLpB;;;;;;;;;;;;;;GAcG;AACH,wBAAgB,QAAQ,CAAC,KAAK,EAAE,aAAa,GAAG,cAAc,CA2J7D"}

package/dist/metal/weldHeat.js

@@ -141,8 +141,11 @@ function calculateCoolingTime(heatInput, thickness, preheatTemp) {
         const tempTerm = 1 / (500 - T0) - 1 / (800 - T0);
         t85 = factor * heatInput * tempTerm;
     }
-    // Clamp to reasonable range (0.5s - 300s)
-    return Math.max(0.5, Math.min(300, t85));
+    // Clamp to the model's validity range (0.5s - 300s). Realistic inputs do land outside it
+    // (thin-sheet GTAW at low heat input gives raw t8/5 ≈ 0.39s), so report the clamp — otherwise
+    // varying thickness below the floor produces identical outputs with no explanation.
+    const value = Math.max(0.5, Math.min(300, t85));
+    return { value, clamped: value !== t85 };
 }
 /**
  * Calculate maximum HAZ hardness using Yurioka formula with cooling rate
@@ -172,8 +175,12 @@ function calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime) {
         coolingFactor = 0.9; // Slow cooling - less hardening
     }
     const HV_max = HV_base * coolingFactor;
-    // Clamp to realistic range (150-700 HV)
-    return Math.min(700, Math.max(150, roundTo(HV_max, 0)));
+    // Clamp to the Yurioka model's calibrated range (150-700 HV). Stainless and cast-iron
+    // compositions push HV_base far past 700 (e.g. cast iron ≈ 4200), so a silent clamp renders
+    // hardness flat across current/composition sweeps — report it so callers treat the value as
+    // a bound, not a prediction.
+    const value = Math.min(700, Math.max(150, roundTo(HV_max, 0)));
+    return { value, clamped: value !== roundTo(HV_max, 0) };
 }
 /**
  * Calculate welding heat input, cooling time, and preheating requirements.
@@ -183,6 +190,11 @@ function calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime) {
  * sentences) and `recommendationCodes` (stable `{ code, params }` entries for
  * i18n). `preheatTemp.source` likewise has a stable `preheatTemp.sourceCode`.
  *
+ * Both `coolingTime_t85` (model range 0.5-300 s) and `hazHardnessMax` (150-700 HV) are
+ * clamped to their models' validity ranges; when that happens `coolingTimeClamped` /
+ * `hazHardnessClamped` is set and the reported number is a boundary value, not a prediction
+ * (at the 700 HV ceiling it is a lower bound — stainless and cast iron compositions hit it).
+ *
  * @throws {RangeError} voltage, current, travelSpeed, or thickness is not positive
  */
 export function weldHeat(input) {
@@ -234,10 +246,10 @@ export function weldHeat(input) {
     const preheatTemp = getPreheatTempAWS(carbonEquivalent, thickness, heatInput);
     const interpassTemp = getInterpassTemp(baseMetal);
     // Calculate cooling time t8/5
-    const coolingTime_t85 = calculateCoolingTime(heatInput, thickness, preheatTemp.min);
+    const { value: coolingTime_t85, clamped: coolingTimeClamped } = calculateCoolingTime(heatInput, thickness, preheatTemp.min);
     const coolingRate = 300 / coolingTime_t85; // (800-500)/t8/5
     // Estimate maximum HAZ hardness with cooling rate consideration
-    const hazHardnessMax = calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime_t85);
+    const { value: hazHardnessMax, clamped: hazHardnessClamped } = calculateHAZHardness(C, Mn, Cr, Mo, V, Ni, Si, coolingTime_t85);
     // Determine hydrogen control level required
     let hydrogenLevel;
     if (carbonEquivalent > 0.50 || hazHardnessMax > 400 || crackingRisk === 'veryHigh') {
@@ -285,7 +297,13 @@ export function weldHeat(input) {
         recommendations.push('Consider post-weld heat treatment (PWHT) per AWS D1.1 Table 5.12');
         recommendationCodes.push({ code: 'pwht', params: {} });
     }
-    if (hazHardnessMax > 350) {
+    if (hazHardnessClamped && hazHardnessMax === 700) {
+        // Prediction exceeded the model ceiling — presenting "700 HV" as the expected value would
+        // understate the risk (white cast iron HAZ genuinely exceeds 700 HV).
+        recommendations.push('HAZ hardness prediction exceeds model ceiling (>700 HV) - treat value as a lower bound; control cooling rate and consider PWHT');
+        recommendationCodes.push({ code: 'hazHardnessCapped', params: { cap: 700 } });
+    }
+    else if (hazHardnessMax > 350) {
         recommendations.push(`High HAZ hardness expected (${hazHardnessMax} HV) - control cooling rate and consider PWHT`);
         recommendationCodes.push({ code: 'highHazHardness', params: { hazHardnessMax } });
     }
@@ -309,10 +327,12 @@ export function weldHeat(input) {
         carbonEquivalent: roundTo(carbonEquivalent, 3),
         carbonEquivalentPcm: roundTo(carbonEquivalentPcm, 3),
         coolingTime_t85: roundTo(coolingTime_t85, 1),
+        coolingTimeClamped,
         coolingRate: roundTo(coolingRate, 1),
         preheatTemp,
         interpassTemp,
         hazHardnessMax,
+        hazHardnessClamped,
         crackingRisk,
         hydrogenLevel,
         recommendations,