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<p>Friction Stir Welding (FSW) has emerged as a major solid-state joining technology since its development in 1991, offering significant advantages over conventional fusion welding methods, including reduced distortion, superior joint quality, and enhanced environmental protection. This review provides a comprehensible overview of recent advances in FSW technology, focusing on its fundamental mechanisms, process variants, and expanding industrial applications. The paper first outlines the core principles of FSW and microstructural evolution within the weld zones — namely the Stir Zone (SZ), the Thermo-Mechanically Affected Zone (TMAZ), and the Heat-Affected Zone (HAZ) — as well as how these transformations influence mechanical performance. Subsequently, emerging variants such as Friction Stir Vibration Welding (FSVW), underwater FSW, and hybrid joining approaches are discussed, with particular focus on defect mitigation and performance optimization. Progress in numerical modeling through Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) is examined, particularly for predicting thermal fields, material flow, and residual stress distributions. Persistent challenges are critically analyzed, including tool wear, defect formation mechanisms, and corrosion susceptibility in FSW joints. Contemporary solutions are presented, ranging from advanced tool materials and coatings to AI-assisted process monitoring and post-weld surface treatments such as ball burnishing. This review synthesizes the current state of research and identifies key opportunities for future development, providing a valuable reference for both academic researchers and industrial practitioners working in solid-state joining technologies.</p>

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A review of recent advances in friction stir welding technologies

  • 期刊论文

  • 发表日期：

    2025年11月12日

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  • Lotfi Beghdadi,
  • Mouloud Aissani,
  • Moustafa Boukraa,
  • Abdel Halim Zitouni

摘要

Friction Stir Welding (FSW) has emerged as a major solid-state joining technology since its development in 1991, offering significant advantages over conventional fusion welding methods, including reduced distortion, superior joint quality, and enhanced environmental protection. This review provides a comprehensible overview of recent advances in FSW technology, focusing on its fundamental mechanisms, process variants, and expanding industrial applications. The paper first outlines the core principles of FSW and microstructural evolution within the weld zones — namely the Stir Zone (SZ), the Thermo-Mechanically Affected Zone (TMAZ), and the Heat-Affected Zone (HAZ) — as well as how these transformations influence mechanical performance. Subsequently, emerging variants such as Friction Stir Vibration Welding (FSVW), underwater FSW, and hybrid joining approaches are discussed, with particular focus on defect mitigation and performance optimization. Progress in numerical modeling through Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) is examined, particularly for predicting thermal fields, material flow, and residual stress distributions. Persistent challenges are critically analyzed, including tool wear, defect formation mechanisms, and corrosion susceptibility in FSW joints. Contemporary solutions are presented, ranging from advanced tool materials and coatings to AI-assisted process monitoring and post-weld surface treatments such as ball burnishing. This review synthesizes the current state of research and identifies key opportunities for future development, providing a valuable reference for both academic researchers and industrial practitioners working in solid-state joining technologies.