In the present article, the effects of friction stir welding (FSW) tool plunge depth (TPD) and tool tiltangle (TTA) were investigated on the heat generation and the material flow during solid-statejoining of polycarbonate (PC) sheet experimentally and simulated with computational fluiddynamics (CFD) method. Simulation results showed that increasing heat input (higher TTA andlower TPD) could increase the size of the stir zone. Results indicate that control of TPD and TTAcan improve the material flow near the top surface. The temperature field in the friction stir weldingof PC was anti symmetric to the welding line. Due to the results, the heat generation andtemperature distribution at the advancing side were more than the retreating side in all jointconditions. According to selected parameters, a strong sample was produced at 1.2 TPD and 2.5oTTA. This sample had 92% PC tensile strength, 89% PC flexural strength, and 86% of impactenergy. تفاصيل المقالة