Mathematical modeling of friction stir welding and processing – A short review

This article is a short review of the analytical models for characterizing the thermal field, material flow, heat generated, distributed and losses, visco-plastic behavior, and deformation during severe plastic deformation—a case study of friction stir welding (FSW). The FSW is a solid-state and green joining technique with broad applications in the aerospace, shipbuilding, automotive, and railway industries. The FSW processing parameters influence the thermal distribution, materials flow, and the evolving mechanical properties. The dynamics between the welding parameters form the basis for formulating different mathematical models for the FSW. A comprehensive understanding of the dynamics between parent materials chemistry, tool design, process parameters, and a reliable model is crucial for predicting welds' quality and properties. A summary of models for explaining the materials multiphysics, thermal, and flow modeling has been highlighted. The complexities of the FSW makes it essential to adopt an effective and reliable model for describing the process to bridge the knowledge gap. The reliability of the model has a significant influence on the accuracy of the experimental validation. The relationship between numerical data and experimental results can help make FSW economic and sustainable.