The effect of tool tilt angle has not been appropriately considered in modelling friction stir welding process. In this study, the expressions to determine incomplete contact region caused by tool tilt were derived and experimentally verified. Correspondingly, the axial stress, slip rate, friction coefficient were modified separately in complete and incomplete contact regions. It was found that with the increase of tool tilt angle from 1.5° to 4°, the material flow ability towards the advancing side was enhanced at trailing side, the temperature at shoulder/workpiece interface increased from 788 to 810 K, while that at pin/workpiece interface increased from 777 to 802 K. The calculated interface temperature and the thermo-mechanically affected zone boundary were in good agreement with the measured ones.
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