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The paper presents the results of a mathematical model of the material flow during Friction Stir Welding (FSW) of aluminium alloys using a Finite Element Analysis. The authors presented their work on a two-dimensional visco-plastic model, using User Define Functions (UDF) in a commercial CFD code (FLUENT). The model developed was validated by microstructural investigations on experimental FSW joints and by a comparative analysis of temperature distribution field of the experimental FSW joint and numerical simulated model. The results confirmed that the mathematical model describes with a good precision the material flow and temperature field during FSW process.

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