Advancements in Friction Stir Welding: A Comprehensive Review of Process Variables and Emerging Developments

Friction stir welding (FSW) is a solid-state welding technique widely employed to join materials such as Aluminum (Al), Copper (Cu), Magnesium (Mg), and their respective alloys. These materials find extensive use in industries like transportation, where lightweight materials with superior mechanical properties are in demand due to their reduced mass. Conventional fusion welding methods can adversely affect the mechanical properties of these welds.Over the last two decades, FSW has emerged as a specific and significant advancement in welding technology. Various parameters, including shoulder diameter, shoulder profile, pin length, pin diameter, tool angle, rotating speed, feed rate, and weld speed, play crucial roles in determining weld strength, quality, heat generation, and material mixing.The current research focuses on investigating the process variables that influence the characteristics of welded products. Furthermore, it includes an in-depth exploration of FSW fundamentals, recent advancements, and comprehensive literature reviews.