Friction Stir Welding (FSW) is a new metal-joining process and the temperature distribution during the FSW process was numerically investigated by changing such parameters as rotation speed, the thermal conductivity of the materials to be joined, the location of the tool, and the generating heat. Results indicate that the temperature on the advancing side is higher than that on retreating side. This can be reduced by heating the upstream portion of the retreating side. The mixing of materials was investigated numerically by assuming materials to be many particles connected with springs. The particles near the pin and the shoulder on the advancing side are mixed well. When the temperature is low in the plastic flow region and plastic deformation force is strong, void defects are found behind the advancing side. These results agree with experimental results.

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