{"id":5823,"date":"2026-06-22T12:41:53","date_gmt":"2026-06-22T12:41:53","guid":{"rendered":"https:\/\/www.compassis.com\/?page_id=5823"},"modified":"2026-07-01T09:08:15","modified_gmt":"2026-07-01T09:08:15","slug":"weldpilot","status":"publish","type":"page","link":"https:\/\/www.compassis.com\/en\/weldpilot\/","title":{"rendered":"WeldPilot"},"content":{"rendered":"\n<h3 class=\"wp-block-heading has-text-align-center\">WeldPilot: advanced simulation to industrialise FSW with less uncertainty<\/h3>\n\n\n\n<div class=\"wp-block-columns alignfull is-not-stacked-on-mobile is-layout-flex wp-container-core-columns-is-layout-8f761849 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:66.66%\">\n<p class=\"wp-block-paragraph\">Define parameters, compare options and prepare more focused physical trials for Friction Stir Welding processes. WeldPilot combines thermo-mechanical simulation, expert judgement and knowledge transfer to help your team move towards a more robust and repeatable process window. <\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>The challenge is not trying FSW. The challenge is industrialising it with control. <\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">For a first critical FSW component, every failed trial can consume material, engineering hours and internal confidence. The goal is not to remove physical testing, but to start from a stronger technical hypothesis, reduce unpromising combinations and make clearer decisions across engineering, production and quality. <\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"803\" height=\"208\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/Recuadros_menos-prueba-error_eng.png\" alt=\"Less trial-and-error, Greater process control, Better decisions\" class=\"wp-image-5827\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>What WeldPilot is<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">WeldPilot is a simulation and technical support solution for analysing and optimising Friction Stir Welding processes in industrial environments. It helps study the thermal and mechanical behaviour of the process, material flow, tool influence and key process variables before expanding physical validation. <\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>What it brings to your FSW project<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The platform offers comprehensive modeling capabilities that cover <strong>complex tool geometries, the tool&#8217;s tilt angle<\/strong>, and critical process features, <strong>including frictional heat generation and plastic deformation, thermal dissipation, and material flow.<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Additionally, it features a <strong>particle tracking<\/strong> module to simulate material flow paths, enabling the prediction of internal defects\u2014such as oxide line propagation, voids, and tunnel defects\u2014prior to physical validation.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"1178\" height=\"217\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/ParticleTracking.png\" alt=\"Particle tracking for visualising material flow\" class=\"wp-image-5812\"\/><figcaption class=\"wp-element-caption\">Particle tracking for visualising material flow<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Who it is intended for<\/strong><\/h2>\n\n\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"777\" height=\"378\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/Aportaciones_eng.png\" alt=\"Contributions by WeldPilot\" class=\"wp-image-5829\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1600\" height=\"560\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/process-window-en.png\" alt=\"Process window\" class=\"wp-image-5834\"\/><figcaption class=\"wp-element-caption\">Process window<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Working methodology<\/strong><\/h2>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>Technical assessment:<\/strong> Review of material, thickness, geometry, machine, tool, quality targets and production constraints.<\/li>\n\n\n\n<li><strong>Case definition:<\/strong> Model preparation, boundary conditions, initial parameters and comparison criteria.<\/li>\n\n\n\n<li><strong>Simulation and comparison:<\/strong> Analysis of thermo-mechanical fields, loads, material flow and possible quality indicators.<\/li>\n\n\n\n<li><strong>Interpretaci\u00f3n experta:<\/strong> Translation of numerical results into process decisions, trial hypotheses and recommendations.<\/li>\n\n\n\n<li><strong>Focused trial and learning<\/strong>: Support for physical validation from a clearer baseline and knowledge transfer to your team.<\/li>\n<\/ol>\n\n\n\n<figure class=\"wp-block-image size-full\" id=\"capacidades_tecnicas\"><img loading=\"lazy\" decoding=\"async\" width=\"1400\" height=\"520\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/methodology-en.png\" alt=\"WeldPilot metodology\" class=\"wp-image-5837\"\/><figcaption class=\"wp-element-caption\">WeldPilot metodology<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Technical capabilities<\/strong><\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Coupled thermo-mechanical modelling of the FSW process.<\/li>\n\n\n\n<li>Analysis of heat generation from friction and plastic deformation.<\/li>\n\n\n\n<li>Material flow assessment through velocity fields and particle tracing.<\/li>\n\n\n\n<li>Evaluation of complex tool geometries and tool tilt angle.<\/li>\n\n\n\n<li>Estimation of loads, reaction forces and force footprints.<\/li>\n\n\n\n<li>CAD-to-simulation workflow for faster case preparation.<\/li>\n\n\n\n<li>Local or HPC execution depending on project scope.<\/li>\n\n\n\n<li>Graphical interface for case creation, simulation launch and post-processing.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Industrial applications<\/strong><\/h2>\n\n\n\n<div class=\"wp-block-group is-style-default is-layout-grid wp-container-core-group-is-layout-1c11e405 wp-block-group-is-layout-grid\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"162\" height=\"161\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/Diseno-sin-titulo.png\" alt=\"Blue train logo\" class=\"wp-image-5807\"\/><figcaption class=\"wp-element-caption\">Rail and advanced transport<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/04\/cimne-imp-fsw-application-1.png\" alt=\"\"\/><figcaption class=\"wp-element-caption\">Automotive<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/04\/cimne-imp-fsw-application-2.png\" alt=\"\"\/><figcaption class=\"wp-element-caption\">Aerospace<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/04\/cimne-imp-fsw-application-3.png\" alt=\"\"\/><figcaption class=\"wp-element-caption\">Shipbuilding<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/04\/cimne-imp-fsw-application-4.png\" alt=\"\"\/><figcaption class=\"wp-element-caption\">Energy and advanced manufacturing<\/figcaption><\/figure>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\">Long aluminium joints, panels and structural subassemblies.<\/p>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\">Parameter optimisation and fewer iterations in high-volume or high-value parts.<\/p>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\">Analysis of demanding joints where process control is critical.<\/p>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\">Aluminium components and structures where repeatability matters.<\/p>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\">New FSW applications, advanced materials and special processes.<\/p>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Technology developed on a scientific basis with an industrial focus<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">WeldPilot stems from CIMNE\u2019s advanced expertise in numerical simulation and is tailored for industrial use through COMPASS. This combination brings together computational models, technical know-how, and applied support for real-world manufacturing projects. <\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"360\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/cimne-compass-trust.png\" alt=\"CIMNE\u2013Compass Collaboration\" class=\"wp-image-5759\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Frequently asked questions<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Does WeldPilot replace physical trials?<\/strong><br>No. WeldPilot helps prepare more focused, intelligent and defensible trials. Physical validation remains necessary and depends on material, geometry, machine, tool and quality requirements.  <\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Is it suitable for any FSW part?<\/strong><br>It should not be presented that way. The first step is to review the material, thickness, geometry, tool, machine and industrial objective to define a realistic scope. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>What does it add compared with direct trial-and-error?<\/strong><br>It provides an initial technical hypothesis, supports option comparison and helps reduce unpromising parameter combinations before spending time, material and engineering hours.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Do we need previous FSW experience?<\/strong><br>Not necessarily, but the internal technical team should be involved. The goal is to transfer judgement and help the team make better decisions. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Which sectors can benefit?<\/strong><br>Rail, automotive, aerospace, shipbuilding, energy, advanced transport and manufacturers working with demanding FSW joints.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Do you have a critical FSW project?<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Share your material, thickness, geometry, tool, machine and quality target. We will help you assess how WeldPilot can reduce uncertainty and prepare an initial technical route. <\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:33.33%\">\n<h2 class=\"wp-block-heading\">Links<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><a href=\"#capacidades_tecnicas\" type=\"internal\" id=\"#capacidades_tecnicas\">View simulation capabilities<\/a><\/li>\n\n\n\n<li><a href=\"#contact_form\">Request a technical assessment<\/a><\/li>\n<\/ul>\n\n\n\t\r\n    \t<div class=\"jcarousel-wrapper\">\r\n        <div style=\"text-align: center;\"><a href=\"#\" class=\"jcarousel-control-prev\">&lsaquo;<\/a><\/div>\r\n\t\t<div class=\"wpvc-jcarousel-skin jcarousel\">\r\n\t\t\t<ul id=\"wpvc-carousel\">\r\n\t\t\t\t\t\t\t<li>\r\n\t\t\t\t\t<a target=\"_blank\" href=\"\" title=\"Vistas t\u00e9cnicas\">\r\n\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"1400\" height=\"760\" 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size-full wp-post-image\" alt=\"Interfaz de trabajo\" style=\"width:100%;height:46.67%;max-width:1200px;\" \/>\t\t\t\t\t<\/a>\r\n\t\t\t\t<\/li>\r\n\t\t\t\t\t\t\t<li>\r\n\t\t\t\t\t<a target=\"_blank\" href=\"\" title=\"Force footprints\">\r\n\t\t\t\t\t\t\t\t\t\t<\/a>\r\n\t\t\t\t<\/li>\r\n\t\t\t\t\t\t\t<li>\r\n\t\t\t\t\t<a target=\"_blank\" href=\"\" title=\"Flujo visual\">\r\n\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"520\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/cad-to-simulation-workflow.jpg\" class=\"attachment-full size-full wp-post-image\" alt=\"Flujo visual\" style=\"width:100%;height:43.33%;max-width:1200px;\" \/>\t\t\t\t\t<\/a>\r\n\t\t\t\t<\/li>\r\n\t\t\t\t\t\t\t<li>\r\n\t\t\t\t\t<a target=\"_blank\" href=\"\" title=\"Campos termomec\u00e1nicos para entender el comportamiento local del proceso\">\r\n\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"1200\" height=\"560\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/simulation-fields.jpg\" class=\"attachment-full size-full wp-post-image\" alt=\"Campos termomec\u00e1nicos para entender el comportamiento local del proceso\" style=\"width:100%;height:46.67%;max-width:1200px;\" \/>\t\t\t\t\t<\/a>\r\n\t\t\t\t<\/li>\r\n\t\t\t\t\t\t\t<li>\r\n\t\t\t\t\t<a target=\"_blank\" href=\"\" title=\"Advancing lateral forces\">\r\n\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"569\" height=\"534\" src=\"https:\/\/www.compassis.com\/downloads\/2026\/06\/Advancing_Lateral_forces.png\" class=\"attachment-full size-full wp-post-image\" alt=\"Advancing lateral forces\" style=\"width:100%;height:93.85%;max-width:569px;\" \/>\t\t\t\t\t<\/a>\r\n\t\t\t\t<\/li>\r\n\t\t\t\t     \t<\/ul> \r\n\t\t<\/div>\r\n\t\t<div style=\"text-align: center;\"><a href=\"#\" class=\"jcarousel-control-next\">&rsaquo;<\/a><\/div>\r\n\t<\/div>\r\n\t\t  \r\n\r\n<script 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WeldPilot&hellip; <a class=\"more-link\" href=\"https:\/\/www.compassis.com\/en\/vertical-carousel\/advancing-lateral-forces\/\">Continue reading <span class=\"screen-reader-text\">Advancing lateral forces<\/span><\/a><\/p>\n","protected":false},"author":6,"featured_media":5846,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-5823","page","type-page","status-publish","has-post-thumbnail","hentry","entry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>WeldPilot | Simulation and optimisation of FSW processes<\/title>\n<meta name=\"description\" content=\"WeldPilot combines advanced simulation, consultancy and knowledge transfer to optimise friction stir welding processes and reduce uncertainty prior to physical testing\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, 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