Abstract
Friction Stir Welding (FSW) is a solid-state joining process that involves the stirring of material heated to a plasticized state by frictional heat generated by rotating tool on the workpiece, which leads to the welding of the material. The material flow behaviour during FSW is a key area of study as it is critical to the quality and strength of the welds. Simulation and prediction of material flow during the Friction Stir Welding process give valuable insights into the process that is often difficult to achieve experimentally, therefore the Computational Fluid Dynamics (CFD) has been increasingly used for material flow analysis of the FSW process. This paper reviews the latest studies that use CFD analysis of material flow in FSW and influence of tool geometry, welding parameters, material properties and heat generation. It presents a detailed comparison of CFD findings from different studies and highlights its contributions, findings, and limitations. Finally, the paper discusses the future work directions in CFD simulations for material flow during FSW.