Friction stir welding of aluminium alloys

TLDR

Since its invention in 1991, friction stir welding of aluminium alloys has been extensively studied, revealing key principles of thermal history, metal flow, and parameter effects on microstructure, yet significant gaps remain that warrant further research. Friction stir welding operates by generating a rotating tool that creates a thermal history and metal flow, with process parameters controlling microstructure and defect entrainment; the resulting microstructural evolution and hardness distribution differ between non‑heat‑treatable and heat‑treatable wrought aluminium alloys, and the technique can achieve a wide range of mechanical properties, including residual stress, fracture, fatigue, and corrosion resistance. Friction stir welding of aluminium is maturing into a widely adopted commercial technology with numerous applications.

Abstract

<title/>The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminium alloys since the technique was invented in 1991 is reviewed. The basic principles of FSW are described, including thermal history and metal flow, before discussing how process parameters affect the weld microstructure and the likelihood of entraining defects. After introducing the characteristic macroscopic features, the microstructural development and related distribution of hardness are reviewed in some detail for the two classes of wrought aluminium alloy (non-heat-treatable and heat-treatable). Finally, the range of mechanical properties that can be achieved is discussed, including consideration of residual stress, fracture, fatigue and corrosion. It is demonstrated that FSW of aluminium is becoming an increasingly mature technology with numerous commercial applications. In spite of this, much remains to be learned about the process and opportunities for further research and development are identified.