An analytical model to optimize rotation speed and travel speed of friction stir welding for defect-free joints

Currently the optimum rotation speed and travel speed used in friction stir welding are obtained by trial and error. An analytical model is proposed and tested for optimizing rotation speed and travel speed for defect-free joints. The model is based on the principle of exactly balancing the material flowing from the region ahead of the pin to the rear with an optimum temperature. The calculated optimum operating windows are consistent with experimental results and literature data.