A coupled two-dimensional Eulerian thermo-elasto-viscoplastic model has been developed for modelling the friction stir welding process. First, a coupled thermo-viscoplastic analysis is performed to determine the temperature distribution in the full domain and the incompressible material flow around the spinning tool. Next, an elasto-viscoplastic analysis is performed outside the viscoplastic region to compute the residual stress. Both frictional heat and plastic deformation heat generation are considered in the model. Furthermore, this is the only known model computing residual stress accounting for plasticity caused by both thermal expansion and mechanical deformation due to material spinning. The computed residual stress is verified by comparing to experimentally measured data.
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