Friction Stir Welding

Mintu

Hi, everyone

I'm trying to run a FSW run, I'm using 2025 version of hypermesh, There are tutorials but I cant find the tutorial files in my directory and The tutorial shows Hyperextrude for FSW but what i see is Metal extrusion, FSW is present in Hyperwelds.

When i check the options from the tutorial in my Hyperextrude or Hyperweld there isn't a single option from the tutorial in my screen,

Can anyone suggest me a tutorial a fem file of FSW setup would be grateful

I want to perform transient analysis , static also would be ok

erdem.keskin

Hi,

In 2025 the workflow is different from most of the older tutorials, so the confusion is completely understandable.

FSW is no longer under HyperXtrude. What you see there as “Metal Extrusion” is correct — that module is only for extrusion processes now.

Friction Stir Welding is handled inside HyperWeld in newer versions. Most tutorials showing FSW under HyperXtrude are based on much older releases, and the UI + process setup has changed significantly since 2024.

If you don’t see the same options as in the tutorial, check:

• User Profile (make sure you're in a welding-related profile, not OptiStruct-only)
• Installed modules (FSW requires the welding/process simulation module)
• Whether the tutorial is version-matched (many public examples are 2021–2022)

Regarding solvers:

• For realistic FSW (moving tool + heat + plasticity), you typically need a transient explicit solution like Radioss.
• Static with OptiStruct would only make sense for residual stress evaluation after a thermal step — not for actual process simulation.

For tutorial files, check:

C:\Prgram Files\Altair\2025\hwdesktop\demos\

or your Altair One / Learning Center account. Some installations don’t include demo models by default.

If anyone has a 2024–2025 FSW example (.fem or Radioss deck) using HyperWeld, sharing it here would definitely help — most of the online material is outdated.