Numerical and experimental study of the heat transfer process in friction stir welding

A mathematical model to describe the detailed three-dimensional transient heat transfer process in friction stir welding (FSW) is presented. This work is both theoretical and experimental. An explicit central differential scheme is used in solving the control equations, the heat transfer phenomena during the tool penetrating, the welding and the tool-removing periods that are studied dynamically. The heat input from the tool shoulder is modelled as a frictional heat and the heat from the tool pin is modelled as a uniform volumetric heat generated by the plastic deformation near the pin. The temperature variation during the welding is also measured to validate the calculated results. The calculated results are in good agreement with the experimental data.