**Numerical Simulation of Material Flow and Analysis of Welding Characteristics in Friction Stir Welding Process**

**Haitao Luo 1,2,\*, Tingke Wu 1,3, Peng Wang 1,4, Fengqun Zhao 1,3, Haonan Wang 1,4 and Yuxin Li 1,4**


Received: 5 May 2019; Accepted: 25 May 2019; Published: 28 May 2019

**Abstract:** Friction stir welding (FSW) material flow has an important influence on weld formation. The finite element model of the FSW process was established. The axial force and the spindle torque of the welding process were collected through experiments. The feasibility of the finite element model was verified by a data comparison. The temperature field of the welding process was analyzed hierarchically. It was found that the temperature on the advancing side is about 20 ◦C higher than that on the retreating side near the welding seam, but that the temperature difference between the two sides of the middle and lower layers was decreased. The particle tracking technique was used to study the material flow law in different areas of the weld seam. The results showed that part of the material inside the tool pin was squeezed to the bottom of the workpiece. The material on the upper surface tends to move downward under the influence of the shoulder extrusion, while the material on the lower part moves spirally upward under the influence of the tool pin. The material flow amount of the advancing side is higher than that of the retreating side. The law of material flow reveals the possible causes of the welding defects. It was found that the abnormal flow of materials at a low rotation speed and high welding speed is prone to holes and crack defects. The forming reasons and material flow differences in different regions are studied through the microstructure of the joint cross section. The feasibility of a finite element modeling and simulation analysis is further verified.

**Keywords:** material flow; finite element model; temperature field; microstructure; welding defects
