Friction Stir Welding (FSW) is a solid-state joining process, where work pieces are welded together using a non-consumable pin-tool which rotates and moves along the interface. The joining is due to heat generated by friction between the tool and material. FSW joints show good mechanical properties and the manufacturing process can be preferable over traditional arc welding techniques, especially for thin, plate shaped aluminum components. Accurate and efficient simulations of FSW processes can help manufactures identify optimal processing parameters and ensure high quality welds. While developing the framework, experimental results are used to verify the predicted temperatures, reaction forces and torque as well as material kinematics. A high solution accuracy for these properties is crucial while the overall computational cost must remain low, since, ultimately, the framework is used for industrial applications. At the same time the framework must deal with complex tool geometries, generally provided as STL or STEP files. The key components of the proposed high-performance Finite Element (FE) framework are: • A Eulerian framework to capture the kinematics of the welding process. • Suitable material models and finite element formulations to solve coupled thermo-mechanical problems in an HPC FE framework, including mixed formulations to address fully isochoric material behavior and to enhance strain and stress accuracy. • Advanced adaptive refinement technology, utilizing different mixed formulations [1] and classical adaptive mesh refinement [2] to enhance the solution accuracy in critical regions. • Advanced friction models suitable for FSW to obtain a better agreement of observed temperatures, reaction forces and material kinematics with experimental results. • Embedded Domain Methods (EDM), utilizing original tool geometries, to avoid constant remeshing and to further enhance the efficiency. The complexity of the proposed framework lies in the interoperability of the individual components and the embedding into a fully parallelized HPC framework. [1] H. Venghaus etal. An Accurate Approach to Simulate Friction Stir Welding Processes Using Adaptive Formulation Refinement. Submitted. Finite Elements in Analysis and Design [2] G.B. Barbat etal. Objectivity in quasi-brittle structural failure via adaptive formulation and mesh refinement. Theoretical and Applied Fracture Mechanics, Vol. 122, pp. 103646, 2022.