Abstract
A model is proposed to interpret observed shapes of transverse cross sectional macrostructures in aluminium friction stir welds. The model applies calculus of variations to minimize a functional corresponding to the work done to shear the material rotating around the tool, thus allowing calculation of an average value for the shear stress on the outer shearing surface around the carousel, as a function of the radial position only and independent of the angular position on that surface. The main point is that there is valuable information to be obtained from observing the geometry of the outer shape of the carousel. Thus, a formula is given to calculate the distribution of the average shear stress at the interface between the rotating material and the nearly stationary base material, on the basis of the observed weld shape.
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