A review of tensile, hardness, wear, and microstructural characteristics of friction stir welded/processed composites

Abstract

In this review paper friction stir welding (FSW) of various aluminum matrix composites (AMCs) is highlighted. The use of traditional fusion welding processes such as the TIG/MIG process for joining of AMCs results in the formation of various defects such as porosity, solidification cracks, etc. such defects is formed mainly due to the melting of parent metals due to high heat supply during fusion welding. Such challenges could be overcome by using a solid-state welding process such as FSW, a novel joining process capable to obtain good-quality joints. In this paper, various AMCs joined by FSW are highlighted, especially emphasis given on the tensile, hardness, wear, and microstructural characteristics of AMCs joined by FSW. It is noted that tool material, tool pin profile, type of reinforcement, and selection of process parameters play a significant role in obtaining good-quality joints. FSW microstructure exhibits a homogeneous distribution of reinforcement as a result better joint efficiency is reported by different researchers. However, the integration of FSW with advanced technology tools such as artificial intelligence (AI) and machine learning (ML) is necessary for online quality inspection and monitoring. Such tools will help for obtaining better-quality joints by avoiding the formation of defects in FSW.