A review on friction stir welding of aluminium alloys and the effects on tool geometry

Abstract

Friction stir welding (FSW) is a novel technique used to join similar and dissimilar alloys. Aluminium alloys of 2XXX, 6XXX and 7XXX are reviewed and presented in this paper. In FSW welding process, heat is generated during the process and workpieces are joined without melting the aluminium alloys. The tool moves along the soften surface for joining aluminium alloys. Tool materials, tool geometry, welding speed, rotational speed, axial forces are examined and the effects on welding surfaces after welding process has been analysed. Friction stir welding can be widely used in aviation, marine and vehicle body construction industries because of its mechanical properties where fusion welding process revealed deformities on the welding materials to be joined. In this review article, the recent research of friction stir joining of aluminium alloys and its applications in various industries are explicated, including the quality of weld of aluminium alloys, the evaluation on microstructure in weld nuggets, and tool wear. The conclusion of this review is unequivocally recommended that aluminium alloys are suggested for future research with numerous industrial applications..