Effect of Workpiece/Tool Heat Transfer and Friction Coefficients on Accuracy of Simulated Temperatures and Torques in a Friction Stir Welding Plunge.

Friction stir process models are typically validated by tuning heat transfer and friction coefficients until measured temperatures in either the tool or workpiece, but rarely in both, match simulated results. A three-dimensional finite element model for a tool plunge in an AA 6061-T6 is validated for temperature predictions in both the tool and workpiece using a friction coefficient that varies with time. Peak workpiece temperatures were within 1.