Friction stir welding (FSW) is a promising joining technique offering safety, repeatability, reduced energy consumption, no need for shielding gases and consumables, and no solidification is involved. To date, extensive efforts have been dedicated toward developing a good combination of friction stir welding process parameters, focusing on tool rotation speed and welding speed to produce sound welds with good corrosion resistance. In this review, we highlight the quantified corrosion resistance performances of reported friction stir welded aluminium alloys under electrochemical testing, which can be used as the benchmark for future studies in this field. A general introduction to friction stir welding technology, heat input formulation and welding temperature, corrosion mechanism and effect of welding parameters are discussed. It is followed by challenges and an outlook toward the practical use of friction stir welding technology.
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