Friction Stir Welding (FSW) is a solid-state joining process that is of special interest in joining aluminum and other alloys that are traditionally difficult to fusion weld. The energy required for this joining process is transmitted to the work-pieces through a rotating FSW tool. Modeling attempts, aimed at perfecting the process, rely on assumptions of the contact conditions present between the work-pieces and the FSW tool. Various studies have attempted to define these contact conditions. Both theoretical and experimental studies indicate the contact conditions between the work-piece and weld tool are unknown and may vary during the FSW process. To provide insight into the contact conditions, the objective of this study is to characterize the FSW nugget in terms of swept volume as indicated by the cross-sectional area and symmetry of the FSW nugget over a range of processing conditions.