A brief summary of recent finite element simulation results for the friction stir welding process is presented. The focus of the present study is on the characterisation of material flow around the rotating tool pin. Material flow patterns predicted by finite element simulations are found to compare favourably with experimental observations. The simulation results also reveal that material particles tend to pass and move behind the rotating pin from the trailing side, rather than both sides, of the pin. Possible variations in the material flow pattern due to variations in process parameters are discussed.
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