The friction stir welding (FSW) process is often associated with various defects, which may develop due to the inappropriate choice of process parameters. The visualisation of the defects is often impossible by means of simple experiments. The present work develops a finite element model using a coupled Eulerian–Lagrangian (CEL) approach to investigate commonly occurred defects in the FSW process. The numerical model is framed, in general, to predict multiple defects such as the improper joining of substrates, formation of tunnel defect, excessive flash, voids and other surface irregularities. In principle, the flow of material within and out of the solution domain allows predicting both the surface and subsurface defects. A suitable comparison between simulation and experiments shows the robustness of the developed model.

搅拌摩擦焊 (FSW) 工艺通常伴随着各种缺陷，这些缺陷可能是由于工艺参数选择不当而产生的。缺陷的可视化通常不可能通过简单的实验来实现。目前的工作使用耦合欧拉-拉格朗日 (CEL) 方法开发了一个有限元模型，以研究 FSW 过程中常见的缺陷。数值模型通常用于预测多种缺陷，例如基板连接不当、隧道缺陷的形成、过多的飞边、空隙和其他表面不规则性。原则上，材料在溶液域内外的流动可以预测表面和表面下的缺陷。模拟和实验之间的适当比较显示了所开发模型的稳健性。