This paper intends to provide a perspective on the current development of the friction stir welding (FSW) technology. The industrialisation of the technology and related research were assessed by analysing patent and scientific publications databases. The literature reviews on FSW and related technologies were also collected and analysed. The work performed enabled to understand the main areas of industry/research where the FSW technology is being applied/explored and the geographical distribution of the main players in its implementation/research. The main FSW process variants, the materials already welded/processed using it, as well as the applications envisaged, were also analysed. The data collected shows that the FSW technology, originally developed for the joining of light alloys, became a research tool with interest in several fields of engineering and material science.
ÇamG.Friction stir welded structural materials: beyond Al-alloys. Int Mater Rev. 2011; 56(1):1–48. doi: 10.1179/095066010X12777205875750
6.
ThomasWM, NicholasED.Friction stir welding for the transportation industries. Mater Des. 1997; 18(4–6):269–273. doi: 10.1016/S0261-3069(97)00062-9
7.
MurrLE, LiY, TrilloE, Fundamental issues and industrial applications of friction-stir welding. Mater Technol. 2000; 15(1):37–48.
8.
ThreadgillPL, JohnsonR.The potential for friction stir welding in oil and gas applications. Proceedings of the Fourteenth International Offshore Polar Engineering Conference; 2004.
9.
KalleeSW.Friction stir welders for prefabricated components and panels. Alum Int Today. 2004; 6(4):29.
10.
ShtrikmanMM.Current state and development of friction stir welding part 3. Industrial application of friction stir welding. Weld Int. 2008; 22(11):806–815. doi: 10.1080/09507110802593620
11.
NelsonTW.Friction stir welding – a brief review and perspective for the future. Friction Stir Welding and Processing III as held 2005 TMS Annual Meeting; 2005.
12.
MishraRS, MaZY.Friction stir welding and processing. Mater Sci Eng R Rep. 2005; 50(1–2):1–78. doi: 10.1016/j.mser.2005.07.001
13.
NandanR, DebRoyT, BhadeshiaHKDH.Recent advances in friction-stir welding – process, weldment structure and properties. Prog Mater Sci. 2008; 53:980–1023. doi: 10.1016/j.pmatsci.2008.05.001
14.
ZhangD, LongF, ChenX, Review on research status of friction stir welding technology. Adv Mater Res. 2011; 335–336:379–382. doi: 10.4028/www.scientific.net/AMR.335-336.379
15.
BiroAL, ChenelleBF, LadosDA.Processing, micros-tructure, and residual stress effects on strength and fatigue crack growth properties in friction stir welding: a review. Metall Mater Trans B. 2012; 43:1622–1637. doi: 10.1007/s11663-012-9716-5
16.
PadhyGK, WuCS, GaoS.Auxiliary energy assisted friction stir welding – status review. Sci Technol Weld Join. 2015; 20(8):631–649. doi: 10.1179/1362171815Y.0000000048
17.
KulekciMK, EsmeU, BuldumB.Critical analysis of friction stir-based manufacturing processes. Int J Adv Manuf Technol. 2016; 85(5):1687–1712. doi: 10.1007/s00170-015-8071-5
18.
SitholeK, RaoVV.Recent developments in micro friction stir welding: a review. IOP Conference Series: Materials Science and Engineering. Vol. 114; 2016. p. 1–11.
19.
CookGE, CrawfordR, ClarkDE, Robotic friction stir welding. Ind Robot An Int J. 2004; 31(1):55–63. doi: 10.1108/01439910410512000
BusuN, JaffarullahMS, LowCY, A review of force control techniques in friction stir process. Procedia Comput Sci. 2015; 76:528–533. doi: 10.1016/j.procs.2015.12.331
22.
Le MoalG, DarrasF, ChartierD.On the feasibility of a monitoring system for the friction stir welding process: literature review and experimental study. 2015 IEEE International Conference on Automation Science and Engineering (CASE); 2015. p. 1576–1583.
23.
MendesN, NetoP, LoureiroA, Machines and control systems for friction stir welding: a review. Mater Des. 2016; 90:256–265. doi: 10.1016/j.matdes.2015.10.124
24.
ÇamG, İpekoğluG, KüçükömeroğluT, Applicability of friction stir welding to steels. J Achiev Mater Manuf Eng. 2017; 80(2):65–85.
25.
ÇamG, İpekoğluG.Recent developments in joining of aluminium alloys. Int J Adv Manuf Technol. 2017; 91(5–8):1851–1866. doi: 10.1007/s00170-016-9861-0
26.
PagliaCS, BuchheitRG.A look in the corrosion of aluminum alloy friction stir welds. Scr Mater. 2008; 58(5):383–387. doi: 10.1016/j.scriptamat.2007.10.043
27.
ThreadgillPL, LeonardAJ, ShercliffHR, Friction stir welding of aluminium alloys. Int Mater Rev. 2009; 54(2):49–93. doi: 10.1179/174328009X411136
28.
KumagaiM.Novel solid state joining technology of aluminium: friction stir welding. Weld Int. 2009; 23(5):338–344. doi: 10.1080/09507110802542684
29.
ÇamG, MistikogluS.Recent developments in friction stir welding of al-alloys. J Mater Eng Perform. 2014; 23(6):1936–1953. doi: 10.1007/s11665-014-0968-x
30.
MirandaACO, GerlichAP, WalbridgeS.Aluminum friction stir welds: review of fatigue parameter data and probabilistic fracture mechanics analysis. Eng Fract Mech. 2015; 147:243–260. doi: 10.1016/j.engfracmech.2015.09.007
FondaRW, KniplingKE.Texture development in friction stir welds. Sci Technol Weld Join. 2011; 16(4):288–294. doi: 10.1179/1362171811Y.0000000010
33.
RamachandranKK, MuruganN, ShashiKS.An assessment on friction stir welding of high melting temperature materials. Appl Mech Mater. 2014; 592–594:43–47. doi: 10.4028/www.scientific.net/AMM.592-594.43
34.
SimõesF, RodriguesDM.Material flow and thermo-mechanical conditions during friction stir welding of polymers: literature review, experimental results and empirical analysis. Mater Des. 2014; 59:344–351. doi: 10.1016/j.matdes.2013.12.038
35.
WangD, XiaoBL, NiDR, Friction stir welding of discontinuously reinforced aluminum matrix composites: a review. Acta Metall Sin (English Lett.). 2014; 27(5):816–824. doi: 10.1007/s40195-014-0143-2
36.
SalihOS, OuH, SunW, A review of friction stir welding of aluminium matrix composites. Mater Des. 2015; 86:61–71. doi: 10.1016/j.matdes.2015.07.071
37.
Avettand-FènoëlMN, SimarA.A review about friction stir welding of metal matrix composites. Mater Charact. 2016; 120:1–17. doi: 10.1016/j.matchar.2016.07.010
38.
JohnsonR, ThreadgillPL.Progress in friction stir welding of aluminium and steel for marine applications. Advanced Marine Materials: Technology and Applications; 2003.
39.
MurrLE.A review of FSW research on dissimilar metal and alloy systems. J Mater Eng Perform. 2010; 19(8):1071–1089. doi: 10.1007/s11665-010-9598-0
40.
HusseinSA, TahirASM, HadzleyAB.Characteristics of aluminum-to-steel joint made by friction stir welding: a review. Mater Today Commun. 2015; 5:32–49. doi: 10.1016/j.mtcomm.2015.09.004
41.
SimarA, Avettand-FènoëlMN.State of the art about dissimilar metal friction stir welding. Sci Technol Weld Join. 2017; 22(5):389–403. doi: 10.1080/13621718.2016.1251712
42.
Mubiayi MP, Akinlabi ET. Friction stir welding of dissimilar materials between aluminium alloys and copper – an overview. Proceedings of the World Congress on Engineering, Vol III; 2013.
43.
MehtaKP, BadhekaVJ.A review on dissimilar friction stir welding of copper to aluminum: process, properties, and variants. Mater Manuf Process. 2016; 31(3):233–254. doi: 10.1080/10426914.2015.1025971
44.
GalvãoI, LoureiroA, RodriguesDM.Critical review on friction stir welding of aluminium to copper. Sci Technol Weld Join. 2016; 21(7):523–546. doi: 10.1080/13621718.2015.1118813
45.
ThomasWM, JohnsonKI, WiesnerCS.Friction stir welding - recent developments in tool and process technologies. Adv Eng Mater. 2003; 5(7):485–490. doi: 10.1002/adem.200300355
46.
ShtrikmanMS.Current state and development of friction stir welding (review). Part 2. Improvement of tools and welding method. Weld Int. 2008; 22(10):712–719. doi: 10.1080/09507110802469060
47.
ThompsonB.Tungsten-based tool material development for the friction stir welding of hard metals. Friction Stir Welding and Processing VI; 2011. p. 105–112.
48.
ZhangYN, CaoX, LaroseS, Review of tools for friction stir welding and processing. Can Metall Q. 2012; 51(3):250–261. doi: 10.1179/1879139512Y.0000000015
49.
BistA, SainiJS, SharmaB.A review of tool wear prediction during friction stir welding of aluminium matrix composite. Trans Nonferrous Met Soc China. 2016; 26(8):2003–2018. doi: 10.1016/S1003-6326(16)64318-2
50.
EslamiS, TavaresPJ, MoreiraPMGP.Friction stir welding tooling for polymers: review and prospects. Int J Adv Manuf Technol. 2017; 89:1677–1690. doi: 10.1007/s00170-016-9205-0
51.
LorrainO, SerriJ, FavierV, A contribution to a critical review of friction stir welding numerical simulation. J Mech Mater Struct. 2009; 4(2):351–369. doi: 10.2140/jomms.2009.4.351
52.
MoraitisGA, LabeasGN.Investigation of friction stir welding process with emphasis on calculation of heat generated due to material stirring. Sci Technol Weld Join. 2010; 15(2):177–184. doi: 10.1179/136217109X12537145658779
53.
TutumCC, HattelJH.Numerical optimisation of friction stir welding: review of future challenges. Sci Technol Weld Join. 2011; 16(4):318–324. doi: 10.1179/1362171811Y.0000000011
54.
NetoDM, NetoP.Numerical modeling of friction stir welding process: a literature review. Int J Adv Manuf Technol. 2013; 65:115–126. doi: 10.1007/s00170-012-4154-8
55.
HeX, GuF, BallA.A review of numerical analysis of friction stir welding. Prog Mater Sci. 2014; 65:1–66. doi: 10.1016/j.pmatsci.2014.03.003
56.
KouS, CaoG.Arc-enhanced friction stir welding. US Patent 7,078,647. 2006.
57.
JiS, LiZ, WangY, Joint formation and mechanical properties of back heating assisted friction stir welded Ti-6Al-4V alloy. Mater Des. 2017; 113:37–46. doi: 10.1016/j.matdes.2016.10.012
58.
LiuX, LanS, NiJ.Electrically assisted friction stir welding for joining Al 6061 to TRIP 780 steel. J Mater Process Technol. 2015; 219:112–123. doi: 10.1016/j.jmatprotec.2014.12.002
59.
KumariK, PalSK, SinghSB.Friction stir welding by using counter-rotating twin tool. J Mater Process Technol. 2015; 215:132–141. doi: 10.1016/j.jmatprotec.2014.07.031
60.
ÁlvarezAI, GarcíaM, PenaG, Evaluation of an induction-assisted friction stir welding technique for super duplex stainless steels. Surf Interface Anal. 2014; 46(10–11):892–896. doi: 10.1002/sia.5442
RahmiM, AbbasiM.Friction stir vibration welding process: modified version of friction stir welding process. Int J Adv Manuf Technol. 2017; 90(1–4):141–151. doi: 10.1007/s00170-016-9383-9
63.
HuangYX, WanL, LvSX, New technique of in situ rolling friction stir welding. Sci Technol Weld Join. 2012; 17(8):636–642. doi: 10.1179/1362171812Y.0000000056
64.
ShiL, WuCS, LiuHJ.Analysis of heat transfer and material flow in reverse dual-rotation friction stir welding. Weld World. 2015; 59(5):629–638. doi: 10.1007/s40194-015-0238-z
65.
ZhouL, LiGH, LiuCL, Effect of rotation speed on microstructure and mechanical properties of self-reacting friction stir welded Al-Mg-Si alloy. Int J Adv Manuf Technol. 2017; 89:3509–3516. doi: 10.1007/s00170-016-9318-5
GibsonBT, BallunMC, CookGE, Friction stir lap joining of 2198 aluminum-lithium alloy with weaving and pulsing variants. J Manuf Process. 2015; 18:12–22. doi: 10.1016/j.jmapro.2014.12.002
70.
ChenJ, FujiiH, SunY, Optimization of mechanical properties of fine-grained non-combustive magnesium alloy joint by asymmetrical double-sided friction stir welding. J Mater Process Technol. 2017; 242:117–125. doi: 10.1016/j.jmatprotec.2016.11.021
71.
SuedMK, PonsD, LavroffJ, Design features for bobbin friction stir welding tools: development of a conceptual model linking the underlying physics to the production process. Mater Des. 2014; 54:632–643. doi: 10.1016/j.matdes.2013.08.057
72.
RahimiS, WynneBP, BakerTN.Development of microstructure and crystallographic texture in a double-sided friction stir welded microalloyed steel. Metall Mater Trans A. 2017; 48:362–378. doi: 10.1007/s11661-016-3833-8
73.
Reza-E-RabbyM, RossK, WhalenS, Solid-state joining of thick-section dissimilar materials using a new friction stir dovetailing (FSD) process. Friction Stir Welding and Processing IX; 2017. p. 67–77.
EbrahimianA, KokabiAH.Friction stir soldering: a novel route to produce graphite-copper dissimilar joints. Mater Des. 2017; 116:599–608. doi: 10.1016/j.matdes.2016.12.057
76.
HaghshenasM, Abdel-GwadA, OmranAM, Friction stir weld assisted diffusion bonding of 5754 aluminum alloy to coated high strength steels. Mater Des. 2014; 55:442–449. doi: 10.1016/j.matdes.2013.10.013
77.
PapaefthymiouS, GoulasC, GavalasE.Micro-friction stir welding of titan zinc sheets. J Mater Process Technol. 2015; 216:133–139. doi: 10.1016/j.jmatprotec.2014.08.029
78.
JiS, MengX, ZengY, New technique for eliminating keyhole by active-passive filling friction stir repairing. Mater Des. 2016; 97:175–182. doi: 10.1016/j.matdes.2016.02.088
79.
Mira-AguiarT, VerderaD, LeitãoC, Tool assisted friction welding: A FSW related technique for the linear lap welding of very thin steel plates. J Mater Process Technol. 2016; 238:73–80. doi: 10.1016/j.jmatprotec.2016.07.006
80.
LuanG, LiG, WangW, The fundamental research of the friction flow welding. The 8th International Friction Stir Welding Symposium; 2010.
81.
van der RestC, JacquesPJ, SimarA.On the joining of steel and aluminium by means of a new friction melt bonding process. Scr Mater. 2014; 77:25–28. doi: 10.1016/j.scriptamat.2014.01.008
82.
PanTY.Friction Stir Spot Welding (FSSW) – a literature review. SAE Tech. Pap. No. 2007-01–1702; 2007.
83.
MubiayiMP, AkinlabiET.An overview on friction stir spot welding of dissimilar materials. In: Transactions on engineering technologies. Dordrecht: Springer; 2015. p. 537–549.
84.
BehmandSA, MirsalehiSE, OmidvarH, Filling exit holes of friction stir welding lap joints using consumable pin tools. Sci Technol Weld Join. 2015; 20(4):330–336. doi: 10.1179/1362171815Y.0000000018
85.
ChenK, LiuX, NiJ.Keyhole refilled friction stir spot welding of aluminum alloy to advanced high strength steel. J Mater Process. Technol. 2017; 249:452–462. doi: 10.1016/j.jmatprotec.2017.06.039
86.
PabandiHK, MovahediM, KokabiAH.A new refill friction spot welding process for aluminum/polymer composite hybrid structures. Compos Struct. 2017; 174:59–69. doi: 10.1016/j.compstruct.2017.04.053
87.
SunYF, FujiiH, TakakiN, Microstructure and mechanical properties of mild steel joints prepared by a flat friction stir spot welding technique. Mater Des. 2012; 37:384–392. doi: 10.1016/j.matdes.2012.01.027
88.
MilesMP, KohkonenK, PackerS, Solid state spot joining of sheet materials using consumable bit. Sci Technol Weld Join. 2009; 14(1):72–77. doi: 10.1179/136217108X341193
89.
StevensonR, WangPC.Friction stir riveting – impact of process parameters on joint performance. 2005 ASME International Mechanical Engineering Congress and Exposition; 2005. p. 1001–1009.
90.
ZhangG, ZhangL, KangC, Development of friction stir spot brazing (FSSB). Mater Des. 2016; 94:502–514. doi: 10.1016/j.matdes.2016.01.057
91.
SavolainenK, MononenJ, HänninenH.State-of-the-art of friction stir processing. Steel Res Int. 2006; 77(5):370–376. doi: 10.1002/srin.200606400
92.
MaZY.Friction stir processing technology: a review. Metall Mater Trans A. 2008; 39A(3):642–658. doi: 10.1007/s11661-007-9459-0
93.
AroraHS, SinghH, DhindawBK.Composite fabrication using friction stir processing – a review. Int J Adv Manuf Technol. 2012; 61(9–12):1043–1055. doi: 10.1007/s00170-011-3758-8
94.
SharmaV, PrakashU, KumarBVM.Surface composites by friction stir processing: a review. J Mater Process Technol. 2015; 224:117–134. doi: 10.1016/j.jmatprotec.2015.04.019
HangaiY, UtsunomiyaT, HasegawaM.Effect of tool rotating rate on foaming properties of porous aluminum fabricated by using friction stir processing. J Mater Process Technol. 2010; 210(2):288–292. doi: 10.1016/j.jmatprotec.2009.09.012
97.
HangaiY, TakahashiK, UtsunomiyaT, Fabrication of functionally graded aluminum foam using aluminum alloy die castings by friction stir processing. Mater Sci Eng A. 2012; 534:716–719. doi: 10.1016/j.msea.2011.11.100
98.
SunN, ApelianD.Localized microstructure enhancement via friction stir processing for die cast components. Metall Ital. 2012; 11–12:3–13.
99.
McNelleyTR.Friction stir processing (FSP) and superplasticity. Lett Mater. 2015; 5(3):246–252. doi: 10.22226/2410-3535-2015-3-246-252
100.
PatelVV, BadhekaV, KumarA.Friction stir processing as a novel technique to achieve superplasticity in aluminum alloys: process variables, variants, and applications. Metallogr Microstruct Anal. 2016; 5(4):278–293. doi: 10.1007/s13632-016-0285-x
101.
LiB, ShenY, LeiL, Fabrication and evaluation of Ti3Alp/Ti–6Al–4V surface layer via additive friction-stir processing. Mater Manuf Process. 2014; 29(4):412–417. doi: 10.1080/10426914.2014.892981
102.
AhujaY, IbrahimR, ParadowskaA, Friction stir forming to fabricate copper-tungsten composite. J Mater Process Technol. 2015; 217:222–231. doi: 10.1016/j.jmatprotec.2014.11.024
103.
LiB, ShenY, HuW.Friction-stir nitriding of titanium alloy surface layer. Mater Manuf Process. 2014; 29(4):493–497. doi: 10.1080/10426914.2013.864410
104.
KarthikGM, RamGDJ, KottadaRS.Friction stir selective alloying. Mater Sci Eng A. 2017; 684:186–190. doi: 10.1016/j.msea.2016.12.064
105.
SalehiM, FarnoushH, MohandesiJA.Fabrication and characterization of functionally graded Al-SiC nanocomposite by using a novel multistep friction stir processing. Mater Des. 2014; 63:419–426. doi: 10.1016/j.matdes.2014.06.013
106.
PalanivelS, NelaturuP, GlassB, Friction stir additive manufacturing for high structural performance through microstructural control in an Mg based WE43 alloy. Mater Des. 2015; 65:934–952. doi: 10.1016/j.matdes.2014.09.082
107.
KhodabakhshiF, GerlichAP, SimchiA, Cryogenic friction-stir processing of ultrafine-grained Al–Mg–TiO2 nanocomposites. Mater Sci Eng A. 2014; 620:471–482. doi: 10.1016/j.msea.2014.10.048
108.
SantosTG, LopesN, MachadoM, Surface reinforcement of AA5083-H111 by friction stir processing assisted by electrical current. J Mater Process Technol. 2015; 216:375–380. doi: 10.1016/j.jmatprotec.2014.10.005
109.
XueP, XiaoBL, MaZY.Achieving large-area bulk ultrafine grained Cu via submerged multiple-pass friction stir processing. J Mater Sci Technol. 2013; 29(12):1111–1115. doi: 10.1016/j.jmst.2013.09.021
110.
CostaMI, LeitãoC, RamalhoA, Local improvement of structural steels high-friction properties by friction stir texturing. J Mater Process Technol. 2015; 217:272–277. doi: 10.1016/j.jmatprotec.2014.11.026
111.
BalasubramanianN, MishraRS, KrishnamurthyK.Friction stir channeling: characterization of the channels. J Mater Process Technol. 2009; 209(8):3696–3704. doi: 10.1016/j.jmatprotec.2008.08.036
112.
GandraJ, KrohnH, MirandaRM, Friction surfacing – A review. J Mater Process Technol. 2014; 214(5):1062–1093. doi: 10.1016/j.jmatprotec.2013.12.008
