Torque, power requirement and stir zone geometry in friction stir welding through modeling and experiments

The torque, power requirement and stir zone geometry during friction stir welding of AA2524 aluminum alloy were modeled by solving the equations of conservation of mass, momentum and energy. The model predictions agreed well with the corresponding measured values for a wide range of welding speeds and tool rotational speeds when the heat transfer coefficient and the friction coefficient values were adjusted.