Deciphering the interdependent impact of process parameters in friction stir welding – Part II: extracting generalization insights from the critical review of pure metal welds

ABSTRACT

In Friction stir welding (FSW), significant interdependencies exist between the human-machine interface (HMI) variables for quality joints, the tool design variables, the workpiece material, and its dimensions. Part I of this review examined these interwoven process variables, encoded them as process mechanisms, and statistically assessed how they affect the mechanical efficiencies of ensued joints in different grades/temper of aluminum and copper alloy workpieces. The variance observed in the process parameter windows per workpiece for defect-free, high-quality joints shows material property dependencies. An in-depth understanding of these dependencies could facilitate process parameter tuning for new welding jobs, especially for workpiece materials/alloys developed through recent techniques like additive manufacturing. Hence, Part II of this review critically examines the functional performances of friction stir welded commercially pure metals, aiming to identify how innate workpiece material properties influence the selection of apt process parameters and through comparative inferences, propose generalizations.

KEYWORDS:

• FSW
• commercially pure metals
• functional performance of welded joints
• property-process linkage
• FSW joining mechanisms

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

SAB was supported by the CSIR-TWAS award - FR No. 3240306320; The funding from a project (File No. SP/YO/2019/1123) sanctioned by the Department of Science and Technology (DST), Government of India, under Scheme for Young Scientists and Technologists (SYST), is gratefully acknowledged by the authors.