Abstract
The fundamental knowledge of heat transfer and material flow in friction stir welding (FSW) provides a defect free, structurally sound and reliable weld joint. A sophisticated mathematical model of FSW uses high computing performance devices. This chapter introduces the phenomenological modelling approach via experimental investigation, by interpreting governing mathematical equations and boundary interactions of the process. Detailed finite element formulation of heat transfer and material flow equations are demonstrated. An analytical heat transfer model based on friction mechanism is also illustrated. Several practical issues related to heat transfer and material flow are discussed. FSW has been successfully used to join metallic materials, such as copper, titanium, steel, magnesium and composites. Preheating in a hybrid FSW process is an alternate route to enhance material plasticity along with reduction of plunging forces as compared to conventional FSW. The interaction between thermal, mechanical and metallurgical models is complex, necessitating a multi-scale modelling approach to capture microscopic behaviour. The theoretical investigation on various aspects of FSW explores the possibility of further development of the process model.
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