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The FSW process is a complex problem due to the highly nonlinear and coupled nature of the physical problem. Different physical phenomena occur during the welding process, involving the thermal and mechanical interactions. The temperature field is a function of many welding parameters such as welding speed, welding sequence and environmental conditions. Formation of distortions and residual stresses in workpieces depend on many interrelated factors such as thermal field, material properties, structural boundary conditions and welding conditions. The challenging issues in physical modeling of the FSW process are divided into four parts.

Challenges to Be Tackled in the Computational Modeling and Numerical Simulation of FSW Processes