General thermomechanical model of FSW based on a characteristic temperature for deformation and heat transfer

Abstract This paper presents a coupled model of heat transfer and plastic deformation in friction stir welding (FSW), accounting for the temperature profile substrate near pin. approach is analogous to boundary layer analysis fluid mechanics based on methodology scaling calibration published data. A focusing common conditions FSW, such as relatively slow translation high rotation velocities, thin shear influence shoulder maximum was reformulated. extends previous work by considering flow into pin an improved criterion determining at edge layer. The results are set updated closed-form expressions temperature, thickness layer, stress around pin, torque thermal effect shoulder, applicable all metals. predictions from this verified against comprehensive database experiments. Applications also include accelerated determination procedure variables generalization maps process limits.