Process modelling and simulation – virtual optimisation of welding, additive, and joining processes

TWI applies advanced numerical modelling and simulation to accelerate process development, improve design efficiency, and reduce cost across manufacturing, joining, and additive processes.

Using finite element analysis (FEA) and computational fluid dynamics (CFD), our experts model processes from welding and heat treatment through to additive manufacturing (AM) and non-destructive testing (NDT), helping to predict and control key factors such as residual stress, distortion, microstructure, and fatigue performance.

Our modelling capability covers a wide range of applications, including:

• Arc and electron beam welding simulations to predict thermal profiles and minimise residual stresses.

• Friction stir welding and friction-based processes using CFD and Eulerian techniques to study material flow.

• Additive manufacturing process simulations (Ti, Al, and Ni alloys) to predict distortion and stress evolution – an area where TWI’s expertise is internationally recognised.

• Guided wave modelling for non-destructive evaluation of complex structures.

• Post-weld heat treatment analysis to quantify and optimise stress relaxation.

• Distortion minimisation in complex assemblies such as lightweight panels and pressure vessels.

With decades of experience in both model validation and experimental correlation, TWI provides accurate, application-specific solutions across a broad range of materials and industries — including space, aerospace, energy, and defence.

By integrating digital simulations into process development, TWI helps manufacturers reduce trial-and-error, accelerate qualification, and achieve higher confidence in performance predictions, supporting the transition towards digital twin manufacturing environments.