Heat input during welding is a basic index for weld quality and service properties associated with the resulting microstructure. In this study, the heat inputs during friction stir welding of Al alloy 5083 at various welding parameters were measured by calorimetry. Multiple regression analysis of the data was conducted to determine an empirical equation to estimate the heat input with the input variables. The effect of the heat input on the grain size of the stir zone was also examined, and a good correlation between the grain size and heat input was obtained. This study obtained a systematic relationship between the input variables, heat input and grain size of the stir zone through experimental measurements.
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