An alternative pressure-dependent velocity boundary condition for modeling self-reacting friction stir welding

A pressure-dependent velocity boundary condition is developed based on wear theory for modeling self-reacting friction stir welding using computational fluid dynamics approach, which provides a new perspective in understanding the physics of sliding/sticking transition condition. The importance shear layer weld formation emphasized. Effects speed cross-section geometry can be robustly captured with this newly Computational results show that at higher speed, TMAZ moves towards pin periphery advancing side, corresponds to experimental observations. This tendency could serve as numerical criterion predict void defect formation.