Advanced Joining Technology for Resilient Lightweight Structure: Development of ODFSW for Aluminum Extrusion Panels

The advancement of sustainable, energy-efficient, and eco-friendly infrastructure has encouraged the adoption of lightweight and high-strength materials such as aluminum extrusion panels. These materials are widely applied in strategic sectors, including electric vehicles, high-speed trains, and modular buildings. However, joining these panels poses technical challenges, particularly in ensuring joint strength and durability. Conventional welding methods often lead to defects such as hot cracking, porosity, and thermal distortion, which compromise joint quality, precision, and long-term reliability. As a solution, Friction Stir Welding (FSW) has emerged as a solid-state joining method that delivers high-quality welds without filler metals and with minimal distortion. One of the latest innovations is One-Step Double-Acting Friction Stir Welding (ODFSW), which employs a dual-shoulder configuration rotating simultaneously on both sides of the material. This approach enhances material flow, promotes balanced plastic deformation, and eliminates the need for backing support. This review discusses the development of ODFSW method for joining aluminum extrusion panels and compares them with conventional welding methods. The findings are expected to contribute significantly to the advancement of modern joining technologies that enable the realization of resilient, energy-efficient, and globally competitive lightweight structures.