Analysis of Friction Stir Welding of Aluminum Alloys

Friction Stir Welding (FSW) is a solid-state joining technique that has gained widespread adoption, particularly for aluminum alloys, due to its ability to produce high-quality welds without melting base materials. This comprehensive review focuses on the influence of process parameters on weld characteristics and performance. Compared to conventional fusion welding methods, FSW offers notable advantages, including superior mechanical properties, fewer defects, enhanced corrosion resistance, and lower environmental impact. The review also addresses key challenges such as tool wear, precise process control, and complications arising from welding dissimilar alloys. By synthesizing recent developments and case studies, this work outlines current limitations and proposes future directions for optimizing the FSW process to expand its applicability in critical engineering sectors.