Search

Recently, deteriorated masonry structures aged over 30 years have shown serious structural problems. Simple and rapid maintenance plans are urgently needed for aging masonry structures. Polyurea (PU) is an effective retrofitting material for aging structures due to its easy spray application. This process saves time, reduces costs, and allows the structure to remain in use during retrofitting. However, a general PU is not suitable for retrofitting aged masonry and concrete structures due to its low stiffness. In this study, stiff-type polyurea (STPU) was selected as the reinforcement material for masonry structures. It was developed by modifying the chemical mix of general PU to improve stiffness. To evaluate the strengthening effect of STPU on masonry members under static loading, tests were conducted. The flexural load capacity of masonry beams with STPU-sprayed surfaces was assessed. Three different types of STPU applications were used to select the most efficient strengthening method. Reinforcing masonry structures with STPU allows brittle failure modes to achieve ductile behavior. This improves their structural performance under lateral stresses. The experimental data were used to calibrate FEM models for simulation. These models can be used for future parametric studies and masonry structural design.

In this study, an effective numerical model was developed for the calculation of the deformation of laser-welded 3 mm 304L stainless steel plates with different gaps (0.2 mm, 0.5 mm, and 1.0 mm). The welding deformation would become larger when the welding gaps increased, and the largest deformation values along the Z direction, of 4 mm, were produced when the gap value was 1.0 mm. A larger plastic strain region was generated in the location near the weld seam, since higher plastic deformation had occurred. In addition, the tensile stress model was also applied at the plastic strain zone and demonstrated that a larger welding gap led to a wider residual stress area. Based on the above results, inherent deformations for butt and corner joints were calculated according to inherent strain theory, and the welding formation for the complex structure was calculated with different gaps. The numerical results demonstrated that a larger deformation was also produced with a larger welding gap and that it could reach the highest value of 10.1 mm. This proves that a smaller welding gap should be adopted during the laser welding of complex structures to avoid excessive welding deformation.

This theoretical study analyzes the possibility to use the classical Mott's hypothesis to model the natural fragmentation of cylindrical structures with two or more metal cylinders arranged coaxially. A critical analysis on the validity of the used hypothesis was conducted based on empirical relations and numerical simulations. The established algorithm allows the determination of a fragment mass scale parameter for each individual cylinder, which is why the cumulative distribution of fragments for the entire structure may be calculated. The results obtained for the structures with two and three cylinders, with equal masses or equal wall thicknesses, can be approximated using a modified Mott's distribution formula in which the number of cylinders is used as an additional parameter.

Delamination is a critical failure mode in power electronics packages that can significantly impact their reliability and performance, due to the large amounts of electrical power managed by the most recent devices which induce remarkable thermomechanical loads. The finite element (FE) simulation of this phenomenon is very challenging for the identification of the appropriate modeling tools and their subsequent calibration. In this study, we present an advanced FE modeling approach for delamination, together with fundamental guidelines to calibrate it. Considering a reference power electronics package subjected to thermomechanical loads, FE simulations with a global-local approach are proposed, also including the implementation of a bi-linear cohesive zone model (CZM) to simulate the complex interfacial behavior between the different layers of the package. A parametric study and sensitivity analysis is presented, exploring the effects of individual CZM variables on the delamination behavior, identifying the most crucial ones and accurately describing their underlying functioning. Then, this work gives valuable insights and guidelines related to advanced and aware FE simulations of delamination in power electronics packages, useful for the design and optimization of these devices to mitigate their vulnerability to thermomechanical loads.

This paper presents the results of research aimed at assessing the effectiveness of ten selected constitutive equations for hyperelastic bodies in numerical modeling of the first compression load cycle of a polyurethane elastomer with a hardness of 90 Sh A depending on the methodology for determining the material constants in the constitutive equations. An analysis was carried out for four variants for determining the constants in the constitutive equations. In three variants, the material constants were determined on the basis of a single material test, i.e., the most popular and available in engineering practice, the uniaxial tensile test (variant I), the biaxial tensile test (variant II) and the tensile test in a plane strain (variant III). In variant IV, the constants in the constitutive equations were determined on the basis of all three above material tests. The accuracy of the obtained results was verified experimentally. It has been shown that, in the case of variant I, the modeling results depend to the greatest extent on the type of constitutive equation used. Therefore, in this case it is very important to choose the right equation. Taking into account all the investigated constitutive equations, the second variant for determining the material constants turned out to be the most advantageous.

Previously published articles on anchors have mainly focused on determining the pullout force of the anchor (depending on the strength parameters of the concrete), the geometric parameters of the anchor head, and the effective anchor depth. The extent (volume) of the so-called failure cone has often addressed as a secondary matter, serving only to approximate the size of the zone of potential failure of the medium in which the anchor is installed. For the authors of these presented research results, from the perspective of evaluating the proposed stripping technology, an important aspect was the determination of the extent and volume of the stripping, as well as the determination of why the defragmentation of the cone of failure favors the removal of the stripping products. Therefore, it is reasonable to conduct research on the proposed topic. Thus far, the authors have shown that the ratio of the radius of the base of the destruction cone to the anchorage depth is significantly larger than in concrete (~1.5) and ranges from 3.9-4.2. The purpose of the presented research was to determine the influence of rock strength parameters on the mechanism of failure cone formation, including, in particular, the potential for defragmentation. The analysis was conducted with the finite element method (FEM) using the ABAQUS program. The scope of the analysis included two categories of rocks, i.e., those with low compressive strength (<100 MPa) and strong rocks (>100 MPa). Due to the limitations of the proposed stripping method, the analysis was conducted for an effective anchoring depth limited to 100 mm. It was shown that for anchorage depths <100 mm, for rocks with high compressive strength (above 100 MPa), there is a tendency to spontaneously generate radial cracks, leading to the fragmentation of the failure zone. The results of the numerical analysis were verified by field tests, yielding convergent results regarding the course of the de-fragmentation mechanism. In conclusion, it was found that in the case of gray sandstones, with strengths of 50-100 MPa, the uniform type of detachment (compact cone of detachment) dominates, but with a much larger radius of the base (a greater extent of detachment on the free surface).

In this study, the possibility of using modern AM technologies to produce designed heels for personalized orthopedic footwear with a medium heel was explored. Seven variants of heels were produced using three 3D printing methods and polymeric materials with different natures: PA12 heels made using the SLS method, photopolymer heels made using the SLA method, and PLA, TPC, ABS, PETG, and PA (NYLON) heels made using the FDM method. A theoretical simulation with forces of 1000 N, 2000 N, and 3000 N was performed in order to evaluate possible human weight loads and possible pressure during orthopedic shoe production. The compression test of the 3D-printed prototypes of the designed heels showed that it is possible to replace the traditional wooden heels of hand-made personalized orthopedic footwear with good-quality PA12 and photopolymer heels made using the SLS and SLA methods, but also with PLA, ABS, and PA (NYLON) heels printed using a cheaper FDM 3D printing method. All of the heels made using these variants withstood loads of more than 15,000 N without damage. It was determined that TPC is not suitable for a product of this design and purpose. Due to its greater brittleness, the possibility of using PETG for orthopedic shoe heels must be verified by additional experiments.

The method of radial shear rolling makes it possible to achieve comparable to high pressure torsion (HPT) method ultrahigh degrees of total strain level in combination with the vortex metal flow character for long-length large bulk bars unable by HPT and many other processes of sever plastic deformation (SPD). Sequential rolling of the Zr-1%Nb alloy was carried out under extreme conditions on two radial shear rolling mills with a total diameter reduction ε = 185% and a maximum total strain level = 46 mm/mm. The strain level and its cross-section distribution assessment by finite element method (FEM) simulation was studied. The final bar cross-section structure type distribution detailed study 1 mm resolution by electron back scatter diffraction (EBSD) mapping was performed. A gradient structure with a predominance of the equiaxed ultrafine-grained (UFG) state was found. The deformation level rising did not allow to refine it in the periphery zone more than that obtained nearly middle of the processing, but it allows for significant change in the axial zone structure. The additional large warm deformations by radial shear rolling have no additional grain refinement effect for already 300-600 nm refined zone. An equiaxed UFG structure was obtained in a relatively large volume of the sample with a reduced gradient towards the non-UFG center zone in regard to known works.

Aluminum alloys are one of the most common structural materials. To improve the mechanical properties, an alloy of the Al-Zn-Mg-Ca-Fe system was proposed. In this alloy, when Fe and Ca are added, compact particles of the Al 10 CaFe 2 compound are formed, which significantly reduces the negative effect of Fe on the mechanical properties. Because of the high solidification rate (about 600 K/s) during cylindrical ingot (~33 mm) production, the electromagnetic casting method (ECM) makes it possible to obtain a highly dispersed structure in the cast state. The size of the dendritic cell is ~7 μm, while the entire amount of Fe is bound into eutectic inclusions of the Al 10 CaFe 2 phase with an average size of less than 3 μm. In this study, the effect of radial shear rolling (RSR) on the formation of the structure and hardening of the Al-8%Zn-3.3%Mg-0.8%Ca-1.1%Fe alloy obtained by EMC was studied. Computer simulation of the RSR process made it possible to analyze the temperature and stress-strain state of the alloy and to select the optimal rolling modes. It was shown that the flow features during RSR and the severe shear strains near the surface of the rod (10 mm) provided a refining and decrease in the size of the initial Fe-containing particles.

In order to estimate the crack depth in concrete using time-of-flight, finite element analysis and experiments were performed on non-cracked concrete blocks and 45 mm and 70 mm vertical cracks. As a result of measuring the time-of-flight change by changing the positions of the transmitter and receiver, it was confirmed that the finite element analysis results agreed with the experimental results, and high accuracy was confirmed by various formulas for calculating the depth of defects using the obtained experimental measurements for comparison. In addition to the verification of the simulation and experimental theory, research was conducted through actual field cases, and methodologies for crack detection and depth evaluation for concrete structures were presented, and furthermore, the expected effects of improving the soundness and safety of structures were shown.

The goal of this study was to explore the self-guided machining mechanism of boring and trepanning association (BTA) deep hole drilling and realize precise control of the machining quality. The motion analysis method was used to analyze the center motion trajectory of the drill during the entrance, and the self-guiding mechanism and hole-forming mechanism of BTA deep hole drilling were revealed. Considering the bending deformation of the drilling tube and the tool structure parameters, according to the elastic-plastic deformation theory and Hertzian contact theory, a novel analytical model of the extrusion contact between the guide pads and the hole wall of the BTA deep hole drilling was established for the theoretical prediction of the extrusion deformation and the machining hole diameter. Combined with the finite element method (FEM) simulation model, the variation law of the contact inclination angle, contact stress, and extrusion deformation of the guide pads and the hole wall with the drilling conditions were studied. The total extrusion deformation between the guide pad and the hole wall was between 10 and 50 μm. The maximum error between the FEM simulation results and the test results was 18.1%, and the maximum error between the analytical model results and the test results was 23.6%. The simulation and experimental results showed that the established extrusion contact model could accurately predict the extrusion deformation of the hole wall and the machining hole diameter.

Embossing is a converting process in which the surface of a tissue paper sheet is changed under high pressure, allowing different functions. In this work, the authors intend to study how the embossing pressure affects the main properties of tissue paper, using a laboratory embossing system. An optimum pressure was achieved at 2.8 bar to this embossing laboratory set-up. The effect of pressure when densifying the paper sheet gives it a gain in mechanical strength but no differences in terms of liquid absorbency. The two embossing patterns present different behaviors but both evidence losses in mechanical and softness properties. On the other hand, the finite element method (FEM) does not show clear evidence of how the pressure affects the paper strength. For the deco die, it is possible to observe that the amount of yielding is slightly higher for lower pressure (2.4 bar), but this plasticity state parameter is very similar for 2.8 bar and 3.2 bar. For the micro die, FEM simulations of the manufacturing pressure do not show a considerable impact on the amount of plasticity state of the material; only for 3.2 bar, it shows a change in the pattern of the plasticity state of the paper during the embossing processes. In the end, to achieve a final product with excellent quality, it is important to make a compromise between the various properties.

In this study, the evolution of mechanical properties, microstructure, and residual stresses during selective laser melting of CuSn10 components was studied. To provide a proper material model for the simulations, various CuSn10 parts were manufactured using selective laser melting and examined. The manufactured parts were also used to validate the developed model. Subsequently, a sequentially coupled thermal-mechanical FEM model was developed using the Ansys software package. The developed model was able to deliver the mechanical properties, residual stresses, and microstructure of the additively manufactured components. Due to introducing some simplifications to the model, a calibration factor was applied to adjust the simulation results. However, the developed model was validated and showed a good agreement with the experimental results, such as measured residual stresses using the hole drilling method, as well as mechanical properties of manufactured parts. Moreover, the developed material model was used to simulate the microstructure of manufactured CuSn10. A fine-grain microstructure with an average diameter of 19 ± 11 μm and preferred orientation in the Z-direction, which was the assembly direction, was obtained.

This paper presents the results of a static and dynamic tensile test of an Al7.5Mg aluminium alloy taken from round bars made in the technology of hydrostatic extrusion. It is planned to use the Al7.5Mg aluminium alloy for joining riveted structures. Based on the obtained results, the nominal and true characteristics of the Al7.5Mg aluminium alloy, depending on the strain rate in the range from 0 to 2000 s -1 , were developed. The failure criterion for tension was determined. The material characteristics were approximated by the Johnson-Cook equation, which can be used in CAE (computer-aided engineering) programs to simulate the impact processes. FEM (finite element method) simulation of the impact of the hammer on the part of the riveted aircraft structure was performed. The FEM simulation results were compared with the experimental results on a drop hammer to verify the material model. The following results were obtained: yield strength R e = 395.3 MPa; strength limit R m = 523.1 MPa at deformation 0.067; Young's modulus E = 7.9 × 10 4 MPa. The AL7.5Mg alloy after hydro-extrusion has favourable plastic and strength properties.

Riveted joints are a common way to connect elements and subassemblies in the automotive industry. In the assembly process, tubular rivets are loaded axially with ca. 3 kN forces, and these loads can cause cracks and delamination in the rivet material. Such effects at the quality control stage disqualify the product in further assembly process. The article presents an analysis of the fracture mechanism of E215 low-carbon steel tubular rivets used to join modules of driver and passenger safety systems (airbags) in vehicles. Finite element method (FEM) simulation and material testing were used to verify the stresses and analysis of the rivet fracture. Numerical tests determined the state of stress during rivet forming using the FEM-EA method based on the explicit integration of central differences. Light microscopy (LM), scanning electron microscopy (SEM) and chemical composition analysis (SEM-EDS) were performed to investigate the microstructure of the rivet material and to analyze the cracks. Results showed that the cause of rivet cracking is the accumulation and exceeding of critical tensile stresses in the rivet flange during the tube processing and the final riveting (forming) process. Moreover, it was discovered that rivet fracture is largely caused by structural defects (tertiary cementite Fe,Mn 3 C III along the boundaries of prior austenite grains) in the material resulting from the incorrectly selected parameters of the final heat treatment of the prefabricate (tube) from which the rivet was produced. The FEM simulation of the riveting and structural characterization results correlated well, so the rivet forming process and fracture mechanism could be fully investigated.

The present contribution aims towards a thermo-electro-mechanical characterization of dielectric elastomer actuators (DEA) based on polydimethylsiloxane (PDMS). To this end, an experimental setup is proposed in order to evaluate the PDMS-based DEA behavior under the influence of various rates of mechanical loading, different ambient temperatures, and varying values of an applied electric voltage. To obtain mechanical, electro-mechanical and thermo-mechanical experimental data, the passive behavior of the material, as well as the material's response when electrically activated, was tested. The influence of the solid electrode on the dielectric layer's surface was also examined. Moreover, this work focuses on the production of such DEA, the experimental setup and the interpretation and evaluation of the obtained mechanical hysteresis loops. Finite element modeling approaches were used in order to model the passive and the electro-mechanically active response of the material. A comparison between experimental and simulation results was performed.

Corrugated cardboard has waved cores with small flutes that prevent the use of detailed numerical models of whole structures. Many homogenization methods in the literature overcome this drawback by defining equivalent homogeneous plates with the same mechanical behaviour at a macro-mechanical scale. However, few homogenization works have considered complete structures, focusing mainly on beams or plates. For the first time, this study explores the application of homogenization approaches to larger structures as an aid in their design process. We also considered triple-wall boards rather than single- and double-wall configurations commonly addressed in the literature. To this end, we adapted the homogenization methods proposed by Talbi and Duong to analyze thin-walled stools made of triple-wall corrugated cardboard. Using a progressive design process, we performed an efficient stool design by removing material zones with lower stresses, with 35% less material, 35% lower vertical deflections, and 66% lower stresses than the initial design. Unlike other corrugated cardboard stools, this design comprises just one folded piece instead of three, thus saving storage space. These results demonstrate the utility of homogenization techniques as an aid in the design process of whole structures made of corrugated cardboard. Further research will consider buckling analysis.

Several design parameters affect the reliability of wafer-level type advanced packaging, such as upper and lower pad sizes, solder volume, buffer layer thickness, and chip thickness, etc. Conventionally, the accelerated thermal cycling test (ATCT) is used to evaluate the reliability life of electronic packaging; however, optimizing the design parameters through ATCT is time-consuming and expensive, reducing the number of experiments becomes a critical issue. In recent years, many researchers have adopted the finite-element-based design-on-simulation (DoS) technology for the reliability assessment of electronic packaging. DoS technology can effectively shorten the design cycle, reduce costs, and effectively optimize the packaging structure. However, the simulation analysis results are highly dependent on the individual researcher and are usually inconsistent between them. Artificial intelligence (AI) can help researchers avoid the shortcomings of the human factor. This study demonstrates AI-assisted DoS technology by combining artificial intelligence and simulation technologies to predict wafer level package (WLP) reliability. In order to ensure reliability prediction accuracy, the simulation procedure was validated by several experiments prior to creating a large AI training database. This research studies several machine learning models, including artificial neural network (ANN), recurrent neural network (RNN), support vector regression (SVR), kernel ridge regression (KRR), K-nearest neighbor (KNN), and random forest (RF). These models are evaluated in this study based on prediction accuracy and CPU time consumption.

The purpose of this study is to identify the stress levels that act in inlay and onlay restorations, according to the direction and value of the external force applied. The study was conducted using the Finite Element Method (FEM) of three types of ceramics: pressed lithium disilicate and monolith, zirconia, and three different adhesive systems: self-adhesive, universal, and dual-cure cements. In addition to FEM, the inlay/onlay-dental structure interface analysis was performed by means of Scanning Electron Microscopy (SEM). The geometric models were reconstructed based on computer tomography images of an undamaged molar followed by geometrical procedures of inducing the inlay and onlay reconstructions. The two functional models were then simulated for different orientations of external force and different material properties, according to the considered adhesives and ceramics. The Scanning Electron Microscopy (SEM) was conducted on 30 extracted teeth, divided into three groups according to the adhesive cement type. Both FEM simulation and SEM investigations reveal very good mechanical behavior of the adhesive-dental structure and adhesive-ceramic interfaces for inlay and onlay reconstructions. All results lead to the conclusion that a physiological mastication force applied, regardless of direction, cannot produce a mechanical failure of either inlay or onlay reconstructions. The adhesive bond between the restorations and the dental structure can stabilize the ceramic restorations, resulting in a higher strength to the action of external forces.

Lightweight moldings obtained by microcellular injection molding (MIM) are of great significance for saving materials and reducing energy consumption. For thick-walled parts, the standard injection molding process brings some defects, including a sink mark, warpage, and high shrinkage. Polyamide 66 (PA66)/glass fiber (GF) thick-walled moldings were prepared by MuCell ® technology. The influences of moldings thickness (6 and 8.4 mm) and applied nitrogen pressure (16 and 20 MPa) on the morphology and mechanical properties were studied. Finally, the microcellular structure with a small cell diameter of about 30 μm was confirmed. Despite a significant time reduction of the holding phase (to 0.3 s), high-performance PA66 GF30 foamed moldings without sink marks and warpage were obtained. The excellent strength properties and favorable impact resistance while reducing the weight of thick-walled moldings were achieved. The main reason for the good results of polyamide composite was the orientation of the fibers in the flow direction and the large number of small nitrogen cells in the core and transition zone. The structure gradient was analysed and confirmed with scanning electron microscopy (SEM) images, X-ray micro computed tomography (micro CT) and finite element method (FEM) simulation.

The chip is the core component of the integrated circuit. Degradation and failure of chip solder joints can directly lead to function loss of the integrated circuit. In order to establish the degradation model of chip solder joints under coupled stress, this paper takes quad flat package (QFP) chip solder joints as the study object. First, solder joint degradation data and failure samples were obtained through fatigue tests under coupled stress. Three types of micro failure modes of solder joints were obtained by scanning electron microscope (SEM) analysis and finite element model (FEM) simulation results. Second, the characterization of degradation data was obtained by the principal component of Mahalanobis distance (PCMD) algorithm. It is found that solder joint degradation is divided into three stages: strain accumulation stage, crack propagation stage, and failure stage. Later, Coffin-Manson model and Paris model were modified based on the PCMD health index and strain simulation. The function relationship between strain accumulation time, crack propagation time, and strain was determined, respectively. Solder joint degradation models at different degradation stage were established. Finally, through strain simulation, the models can predict the strain accumulation time and failure time effectively under each failure mode, and their prediction accuracy is above 85%.

Zr-Cu filler metal is proposed for SiC ceramic under special working conditions, as a novel type of the active filler metal, the difference of physical and chemical properties between SiC ceramic and Zr-Cu filler metal leads to greater residual stress in the joint, which affects the mechanical properties of brazing SiC ceramic joint. Based on the finite element method (FEM) simulation, the residual stress of the joint is simulated to guide the design of Zr-based filler metal and formulation of brazing process. The residual stress distribution of SiC ceramic joints brazed at 1200 °C with different thickness of the filler metal and cooling rate is simulated by ANSYS software. The simulation results of the residual stress are verified by brazing experiments and XRD measurements. The results show that the simulated residual stress of the joint is mainly axial compressive stress. The axial compressive stresses are the lowest when the filler metal thickness is 0.1 mm and the cooling rate is 2 °C /min, and increase with the increase of the filler metal layer thickness and cooling rate. The shear strength of the brazed SiC ceramic joint that achieves the highest with 2 °C /min is about 72 MPa, and then decreases with the increase of cooling rate. The experimental test of residual stress in different locations of the brazed SiC ceramic joint basically coincide with the FEM simulation.

A case study of a failed humeral shaft locking compression plate is presented, starting with a clinical case where failure occurred and an implant replacement was required. This study uses finite element method (FEM) in order to determine the failure modes for the clinical case. Four loading scenarios that simulate daily life activities were considered for determining the stress distribution in a humeral shaft locking compression plate (LCP). Referring to the simulation results, the failure analysis was performed on the explant. Using fracture surface investigation methods, stereomicroscopy and scanning electron microscopy (SEM), a mixed mode failure was determined. An initial fatigue failure occurred followed by a sudden failure of the plate implant as a consequence of patient's fall. The fracture morphology was mostly masked by galling; the fractured components were in a sliding contact. Using information from simulations, the loading was inferred and correlated with fracture site and surface features.

The in-situ TiB₂/7050Al composite is a new kind of Al-based metal matrix composite (MMC) with super properties, such as low density, improved strength, and wear resistance. This paper, for a deep insight into its cutting performance, involves a study of the chip formation process and finite element simulation during orthogonal cutting in-situ TiB₂/7050Al MMC. With chips, material properties, cutting forces, and tool geometry parameters, the Johnson-Cook (J-C) constitutive equation of in-situ TiB₂/7050Al composite was established. Then, the cutting simulation model was established by applying the Abaqus-Explicit method, and the serrated chip, shear plane, strain rate, and temperature were analyzed. The experimental and simulation results showed that the obtained material's constitutive equation was of high reliability, and the saw-tooth chips occurred commonly under either low or high cutting speed and small or large feed rate. From result analysis, it was found that the mechanisms of chip formation included plastic deformation, adiabatic shear, shearing slip, and crack extension. In addition, it was found that the existence of small, hard particles reduced the ductility of the MMC and resulted in segmental chips., Competing Interests: All authors declare no conflict of interest.

The present study was carried out to evaluate how the friction stir spot welding (FSSW) process parameters affect the temperature distribution in the welding region, the welding forces and the mechanical properties of the joints. The experimental study was performed by means of a CNC machine tool obtaining FSSW lap joints on AA7050 aluminum alloy plates. Three thermocouples were inserted into the samples to measure the temperatures at different distance from the joint axis during the whole FSSW process. Experiments was repeated varying the process parameters, namely rotational speed, axial feed rate and plunging depth. Axial welding forces were measured during the tests using a piezoelectric load cell, while the mechanical properties of the joints were evaluated by executing shear tests on the specimens. The correlation found between process parameters and joints properties, allowed to identify the best technological window. The data collected during the experiments were used to validate a simulation model of the FSSW process, too. The model was set up using a 2D approach for the simulation of a 3D problem, in order to guarantee a very simple and practical solution for achieving results in a very short time. A specific external routine for the calculation of the thermal energy due to friction acting between pin and sheet was developed. An index for the prediction of the joint mechanical properties using the FEM simulations was finally presented and validated.