WeldPilot leverages the expertise of CIMNE’s research cluster in Solid and Fluid Simulation for Industrial Processes, a highly-specialized team of researchers with a solid background, focusing on developing advanced computational models with direct industrial applicability.
WeldPilot is a high-performance simulation tool developed at CIMNE and comercialised by COMPASS for the analysis and optimization of Friction Stir Welding (FSW) processes in industrial environments. Designed for integration with HPC systems, it enables accurate and efficient modelling of both thermal and mechanical aspects of the process, significantly reducing simulation time while ensuring predictive reliability.
The platform provides detailed modelling capabilities, covering complex tool geometries, tool tilt angle, and key process features such as frictional and plastic heat generation, thermal dissipation, and material flow. It also incorporates a particle-tracking module to simulate material trajectories, allowing prediction of internal defects such as oxide line propagation, voids, and tunnel defects before physical validation.
WeldPilot serves industries including automotive, aerospace, rail, and shipbuilding. By facilitating early defect detection and process optimization, it contributes to improved weld quality, shorter development cycles, and lower manufacturing costs.
Mesh generation
Material tracing
Pressure distribution, temperature evolution, and velocity field
Oxide line propagation in FSW
In action
Features
Rapid, accurate FSW simulation
Predict temperature, pressure, and material flow fields orders of magnitude faster than full-order FEM simulations.
Digital twin-ready process optimization
Explore and optimize FSW parameters efficiently, across diverse tool geometries and operating conditions.
Improved quality and defect reduction
Particle-tracking module to simulate material trajectories, allowing prediction of internal defects before physical validation.
Lower material and energy consumption
Optimize process parameters to reduce waste and energy usage while maintaining high-quality welds.
Applications
Automotive welding optimization
Aerospace structural joints
Naval and shipbuilding components
Manufacturing with advanced materials
Interested?
WeldPilot has been developed by CIMNE and comercialised by COMPASS.
If you want to learn more about our FSW expertise or how we can help your organization, send us an email!