Processing, Microstructure, and Residual Stress Effects on Strength and Fatigue Crack Growth Properties in Friction Stir Welding: A Review

The purpose of this review is to provide a comprehensive overview of friction stir welding (FSW), as well as to introduce current research and applications involving this relatively new process. FSW is a new, efficient way of joining metal alloys that are considered unsuitable for welding via conventional fusion joining methods, and is capable of welding dissimilar metals with ease. This process also has the benefit of being solid-state, which mitigates the need for liquid filler metals that are common with conventional fusion welding techniques. This review will examine different facets of the FSW process, exploring the resulting static and dynamic properties and factors that influence these properties including weld zone boundaries, grain refinement, residual stress, and addition of reinforcing particles. Highlights of current research in this area and applications of this process in various industries will also be presented and discussed.