In the present research, a coupled Eulerian-Lagrangian model is developed to predict the forces and defects produced from AA6063 friction stir welding process. Furthermore, the obtained results from the developed model were validated experimentally by performing the welding process at different rotational and welding speed values. The results revealed an appearance of tunnel defect at all welded joints with surface flash. The current model successfully predicted both defects' evolution. Additionally, it also generated force measurements comparable to those obtained experimentally. In addition, the developed Coupled Eulerian-Lagrangian model successfully predicted the generated force and the defects during friction stir welding process with maximum error of 14% and 18%. However, it failed in predicting the tunnel positions. In terms of the tensile strength, the largest tensile strength value was at 1250rpm and 50 mm/min, whereas the lowest one was at 1000 rpm and 25 mm/min. Moreover, the fracture locations were at the advancing side of all the welded joints.
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