| Summary: | Friction stir welding (FSW) is a relatively new solid-state joining process which is considered energy efficient, eco-friendly and versatile. High stress and strain occur at the rotating tool, consisting of a pin (probe) and a shoulder, during the friction stir process. The geometrical design of the tool has some impact in terms of stress and strain once static load is applied against the tool. In this work, specific stress can be found on the tool due to the plunging and travel process that is analysed using finite element method. In the present work, a steady state finite element stress analysis of friction stir welding was carried out using CATIA V5 software. The critical points of the FSW tool are located mainly on the edge between the shoulder and the pin, where a large amount of stress is found and further leads to failure or tool defects. This critical stress and strain can be reduced by enlarging the diameter size of the pin and increasing tool life. © 2015 The Authors.
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