The Effect of Friction Stir Welding Parameters on the Weldability of Aluminum Alloys with Similar and Dissimilar Metals: Review

Abstract

The solid-state welding method known as friction stir welding (FSW) bonds two metallic work parts, whether the same or different, by plastically deforming the base metal. The frictional resistance between both metallic workpieces causes them to produce heat, which produces plastic deformation and welds them. However, the weldability and strength of FSW joints mainly depend on the FSW parameters. This review work highlights the previous research work on the FSW parameters and their effects on the weldability and quality of the aluminum alloys joined with similar and dissimilar metals through the FSW method. About 150 research studies were systematically reviewed, and the articles included data from peer-reviewed journals. It has been concluded that the key parameters, including welding speed, “rotational speed”, “plunge depth”, “spindle torque”, “shoulder design”, “base material”, “pin profile” and “tool type”, significantly affect the weldability of the aluminum joint through the FSW method. Also, the selection of these parameters is important and fundamental as they directly affect the joint. It is recommended that future work focuses on FSW for aluminum. Among these, the most essential is the application of artificial intelligence (AI) techniques to select the optimum FSW parameters for aluminum welding.

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

“…Additionally, the process can be slower than traditional welding methods, which can be a disadvantage in some applications. Many studies conducted in the last fifteen years have studied the FSW of dissimilar Al alloy joints focusing on several aspects such as process optimization, effect of process parameters, microstructure, mechanical properties, and heat treatments [31][32][33][34][35]. The aim of this review is to present that the process parameters influence the properties of a friction stir welded joint between two dissimilar aluminum alloys.…”

Studies on the Quality of Joints and Phenomena Therein for Welded Automotive Components Made of Aluminum Alloy—A Review

“…Also, Khalafe et al [293] revealed in their review that various artificial intelligence (AI) techniques, including fuzzy logic, artificial neural fuzzy interfacing system (ANFIS), heuristic methods, heuristic algorithms, wavelet methods, machine learning, hybrid systems, and artificial neural networks, facilitate the enhancement of the rate of production with better accuracy for both similar and dissimilar alloys, also including Al ones.…”

New EoL Routes of Al-Li Aircraft Integral LBW and FSW Welded Panels including New Cr-Free Coatings

“…Therefore, it is necessary to further develop the process to understand the mechanisms that involve the weld formation. Previous works have demonstrated the strong influence that the welding parameters and probe geometry have on the typical defect features of the friction stir welded lap joints (hook and cold lap defects) [9][10][11]. Moreover, it is of paramount importance to consider the effect that other manufacturing variables, such as sealant application or surface treatment, can have on the mechanical performance and manufacturability of the joints.…”