Subscribe to our newsletter to receive the latest news and events from TWI:

Subscribe >
Skip to content

Finite Element Analysis (FEA) Services

Our work using finite element analysis (FEA) techniques provides safety and reliability assurance and reduces manufacturing and operating costs for member companies across a broad range of industries.

Finite element analysis provides cost savings and reliability assurance via:

  • simulation of the behaviour of structures under static, dynamic and cyclic loads
  • weld modelling to accurately predict residual stress and distortion
  • modelling of inspection and testing procedures to provide reliable input data to engineering critical assessments (ECAs).

Our expertise

We use FEA, computational fluid dynamics (CFD), and related numerical techniques for a broad range of applications. These include:

  • support for  fitness for service (FFS) assessments, engineering critical assessments (ECAs), and design verifications, when FEA and fracture mechanics expertise is required by the relevant standards, such as BS 7910, API 579, R6 and BS 7608
  • simulation of joining processes using FEA and CFD to predict residual stresses and distortion
  • using FEA to extend the capabilities of ultrasonic non-destructive testing (NDT) techniques, notably guided wave inspection
  • design optimisation
  • use of digital image correlation for non-contact measurement of displacement, including bespoke applications
  • inverse analysis to carry out measurements based on FEA simulations.

TWI uses state-of-the art commercial software to perform FEA, as well as developing in-house software tools to supplement the commercial codes.


Industry sectors that benefit from our FEA services include oil and gas, power generation, transport, infrastructure and medical.

Welding simulation and manufacturing process optimisation, for example, can reduce the cost of mitigation of distortion during manufacture. ECAs and improvements in the capability of guided wave inspection can increase the allowable time between inspections, and therefore reduce operating costs. ECAs are also used to support decisions about life extension, repair and replacement.

Effective design of components allows our clients to achieve a satisfactory balance between factors such as performance within specifications, weight, cost, complexity and sustainability. Finding the correct balance improves profitability and can also provide new unique selling points.

The interdisciplinary approach taken by TWI is of great value during these activities. Strong links between laboratory and modelling simulation allow the collation and use of high-quality input data for models, and their validation through physical testing.

For more information please email: