In the present work, an experimental study and finite element based numerical analysis of friction stir processing (FSP) of AZ31 magnesium alloy in varying cooling mediums namely air, liquid nitrogen, and water, have been performed. Processing in these three cooling mediums led to varying degrees of grain refinement in the stir zone. Maximum refinement was observed in case of processing in water where an initial grain size of 48 µm was refined to 3 µm. Apart from differences in grain size, macrostructure observations indicating the stir zone dimensions showed steep contrast. Finite element based numerical analysis of friction stir processing was performed for the three cooling mediums, which could effectively capture the experimental observations of stir zone dimensions and temperature profiles.
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