Process, Performance, and Role of Friction Stir Welding for Joining Aluminium Alloys: A Comprehensive Review

It is a solid-state welding technique that bonds materials below their melting point, offering important benefits over fusion welding, such as superior mechanical properties and reduced distortion. This paper comprehensively reviews recent FSW research, detailing the core ideas behind the procedure and systematically analyzing critical parameters for welding (speed of rotation, traverse speed, Axial force), work piece materials, tool design and composition, and work piece dimensions. Defect formation in FSW joints and mitigation strategies are examined. The study further evaluates the advantages and disadvantages of FSW, discusses its current industrial applications, and explores prospects. By consolidating foundational and emerging research, this work provides a holistic overview of FSW as a transformative joining technology.