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A numerical model of friction stir welding has been optimized to fit experimental data of three welds of 304L stainless steel at various weld velocities and spindle speeds. Optimization was used to determine the values of six model parameters that describe phenomena during the welding process. The parameter values were then compared to each other and to the default values. Predicted tool slip was determined to vary significantly with differing weld conditions. The coefficient of friction was also shown to vary. The mechanical efficiency of the three welds was predicted to range between 0.80 – 0.90. Optimization of additional welds is suggested so that correlations of the model parameters to weld velocity and spindle speed can be determined.

Optimization of a numerical model of three-dimensional heat transfer during friction stir welding of 304L stainless steel