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Original Article

Friction stir welding of aluminium alloys

Pages 49-93 | Published online: 18 Jul 2013

Keep up to date with the latest research on this topic with citation updates for this article.

Read on this site (81)

Xiushuo Zhang, Yu’e Ma, Wenya Li, Wei Huang, Weihong Zhang & ZhenHai Wang. (2023) A review of residual stress effects on fatigue properties of friction stir welds. Critical Reviews in Solid State and Materials Sciences 48:6, pages 775-813.
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Danka Labus Zlatanovic, Jean Pierre Bergmann, Sebastian Balos, Jörg Hildebrand, Mirjana Bojanic-Sejat & Saurav Goel. (2023) Effect of surface oxide layers in solid-state welding of aluminium alloys – review. Science and Technology of Welding and Joining 28:5, pages 331-351.
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Tianhao Wang, Md Reza-E-Rabby, Hrishikesh Das, Glenn J. Grant & Scott Whalen. (2023) Friction stir welding of thick 7175 aluminium alloy plates for deepwater riser applications. Science and Technology of Welding and Joining 0:0, pages 1-10.
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K. N. Uday & G. Rajamurugan. (2023) Influence of process parameters and its effects on friction stir welding of dissimilar aluminium alloy and its composites – a review. Journal of Adhesion Science and Technology 37:5, pages 767-800.
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E. B. Fonseca, A. Z. Fatichi, M. Terada, A. F. S. Bugarin, J. Rodriguez, Isolda Costa & A. J. Ramirez. (2023) Quantitative analysis of susceptibility to intergranular corrosion in alloy 625 joined by friction stir welding. Corrosion Engineering, Science and Technology 58:2, pages 138-144.
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Vaibhav Gaikwad, Satish Chinchanikar & Omkar Manav. (2023) Investigation and multi-objective optimization of friction stir welding of AA7075-T651 plates. Welding International 37:2, pages 68-78.
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Gurel Çam, Vahid Javaheri & Akbar Heidarzadeh. (2023) Advances in FSW and FSSW of dissimilar Al-alloy plates. Journal of Adhesion Science and Technology 37:2, pages 162-194.
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Dhilip A, Jayakrishnan Nampoothiri, Senthilkumar M & Kirubanandan N. (2022) Machine learning predictive approaches for hot crack mitigation in modified TIG welded AA7075 joints. Materials and Manufacturing Processes 0:0, pages 1-13.
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Devang Sejani, Wenya Li & Vivek Patel. (2022) Stationary shoulder friction stir welding – low heat input joining technique: a review in comparison with conventional FSW and bobbin tool FSW. Critical Reviews in Solid State and Materials Sciences 47:6, pages 865-914.
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Danilo Ambrosio, Egoitz Aldanondo, Vincent Wagner, Gilles Dessein, Christian Garnier, Javier Vivas & Olivier Cahuc. (2022) A semi-empirical model for peak temperature estimation in friction stir welding of aluminium alloys. Science and Technology of Welding and Joining 27:7, pages 491-500.
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Praveen Kumar & Satpal Sharma. (2022) Effect of high tool rotational speed and pin diameter on mechanical properties, microstructure and formability of friction stir tailor welded blanks. Advances in Materials and Processing Technologies 8:4, pages 4613-4641.
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R. Venkateswara Rao & M. Senthil Kumar. (2022) Effect of pin geometry on material flow characteristics of friction stir welded dissimilar AA6061/AA2014 alloys. Australian Journal of Mechanical Engineering 20:2, pages 552-566.
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Mansour Mardalizadeh, Mohammad Ali Safarkhanian & Mehrdad Khandaei. (2021) Macro- and microstructure analysis and mechanical characteristics of thick AlMg5 alloy plates joined by floating-bobbin friction stir welding. Journal of Adhesion Science and Technology 35:12, pages 1284-1304.
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Shalok Bharti, Nilesh D. Ghetiya & Kaushik M. Patel. (2021) A review on manufacturing the surface composites by friction stir processing. Materials and Manufacturing Processes 36:2, pages 135-170.
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Mansour Mardalizadeh, Mehrdad Khandaei & Mohammad Ali Safarkhanian. (2021) Influence of travel speed on the microstructural evaluation and mechanical characteristics of bobbin tool friction stir-welded thick AA5456-H112 plates. Journal of Adhesion Science and Technology 35:1, pages 90-109.
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Xun Xu, Haidong Yu & Zhangpeng Lin. (2020) Study of residual stress variation with depth of friction stir welded aluminium plates with different thicknesses. Science and Technology of Welding and Joining 25:4, pages 297-302.
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G. H. Li, L. Zhou, S. F. Luo, Z. Y. Du, J. C. Feng & F. X. Meng. (2020) Microstructure and mechanical properties of self-reacting friction stir welded AA2219-T87 aluminium alloy. Science and Technology of Welding and Joining 25:2, pages 142-149.
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L. H. Shah, S. Walbridge & A. Gerlich. (2019) Tool eccentricity in friction stir welding: a comprehensive review. Science and Technology of Welding and Joining 24:6, pages 566-578.
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K. Anil Kumar, S. Natarajan, Muthukannan Duraiselvam & S. Ramachandra. (2019) Synthesis, characterization and mechanical behavior of Al 3003 - TiO2 surface composites through friction stir processing. Materials and Manufacturing Processes 34:2, pages 183-191.
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V. K. Parikh, A. D. Badgujar & N. D. Ghetiya. (2019) Joining of metal matrix composites using friction stir welding: a review. Materials and Manufacturing Processes 34:2, pages 123-146.
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V. M. Sharma, V. Racherla & S. K. Pal. (2019) Friction sintering of brass powder. Advances in Materials and Processing Technologies 5:1, pages 95-103.
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Changyu Zhao, Hua Zhang, Tongge Shao & Chengliang Dou. (2019) Microstructure and corrosion behaviour of Al coating deposited by cold spraying onto FSW AA2219-T87 joint. Corrosion Engineering, Science and Technology 54:1, pages 86-92.
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Mohamed Abu–Okail, Moataz H. Ata, Ahmed Abu-oqail, Ghada M. F. Essa, T. S. Mahmoud & Ibrahim Hassab–Allah. (2018) Production of tailor-welded blanks by vertical compensation friction stir welding technique. Materials Science and Technology 34:16, pages 2030-2041.
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Xun Li, Jinglong Li, Zhongxiang Liao, Feng Jin, Jiangtao Xiong & Fusheng Zhang. (2018) Effect of rotation speed on friction behavior and radially non-uniform local mechanical properties of AA6061-T6 rotary friction welded joint. Journal of Adhesion Science and Technology 32:18, pages 1987-2006.
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V. M. Magalhães, C. Leitão & D. M. Rodrigues. (2018) Friction stir welding industrialisation and research status. Science and Technology of Welding and Joining 23:5, pages 400-409.
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L. Shi, C. S. Wu & Z. Sun. (2018) An integrated model for analysing the effects of ultrasonic vibration on tool torque and thermal processes in friction stir welding. Science and Technology of Welding and Joining 23:5, pages 365-379.
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Z. Y. Ma, A. H. Feng, D. L. Chen & J. Shen. (2018) Recent Advances in Friction Stir Welding/Processing of Aluminum Alloys: Microstructural Evolution and Mechanical Properties. Critical Reviews in Solid State and Materials Sciences 43:4, pages 269-333.
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Jitender Kundu & Hari Singh. (2018) Modelling and analysis of process parameters in friction stir welding of AA5083-H321 using response surface methodology. Advances in Materials and Processing Technologies 4:2, pages 183-199.
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Takashi Yokoyama, Kenji Nakai & Kazuyoshi Katoh. (2018) Tensile properties of 6061-T6 friction stir welds and constitutive modelling in transverse and longitudinal orientations. Welding International 32:3, pages 161-171.
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G. V. B. Lemos, P. H. C. P. Cunha, R. M. Nunes, L. Bergmann, J. F. dos Santos & T. Clarke. (2018) Residual stress and microstructural features of friction-stir-welded GL E36 shipbuilding steel. Materials Science and Technology 34:1, pages 95-103.
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G. V. B. Lemos, S. Hanke, J. F. Dos Santos, L. Bergmann, A. Reguly & T. R. Strohaecker. (2017) Progress in friction stir welding of Ni alloys. Science and Technology of Welding and Joining 22:8, pages 643-657.
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W. J. Brayshaw, M. J. Roy, T. Sun, V. Akrivos & A. H. Sherry. (2017) Iterative mesh-based hardness mapping. Science and Technology of Welding and Joining 22:5, pages 404-411.
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Aude Simar & Marie-Noëlle Avettand-Fènoël. (2017) State of the art about dissimilar metal friction stir welding. Science and Technology of Welding and Joining 22:5, pages 389-403.
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Vahid Farajkhah, Yi Liu & Liam Gannon. (2017) Finite element study of 3D simulated welding effect in aluminium plates. Ships and Offshore Structures 12:2, pages 196-208.
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L. Ji, D. W. Zuo & M. Wang. (2016) Force response characteristics and mechanical properties of friction stir welded AA2024 sheets. Materials Science and Technology 32:18, pages 1892-1898.
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D. Yi, S. Mironov, Y. S. Sato & H. Kokawa. (2016) Effect of cooling rate on microstructure of friction-stir welded AA1100 aluminum alloy. Philosophical Magazine 96:18, pages 1965-1977.
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S. A. Behmand, S. E. Mirsalehi, H. Omidvar & M. A. Safarkhanian. (2016) Single- and double-pass FSW lap joining of AA5456 sheets with different thicknesses. Materials Science and Technology 32:5, pages 438-445.
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U. Donatus, G. E. Thompson, S. Morsch & I.-L. Tsai. (2016) Areas of concern in an anodised dissimilar friction stir weld of AA5083 and AA6082 aluminium alloys. Transactions of the IMF 94:2, pages 70-75.
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H.-S. Shin & M. de Leon. (2016) Weldability assessment of friction stir spot welded lightweight alloys using pin and pinless tools. Science and Technology of Welding and Joining 21:2, pages 99-105.
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Wenya Li, Achilles Vairis, Michael Preuss & Tiejun Ma. (2016) Linear and rotary friction welding review. International Materials Reviews 61:2, pages 71-100.
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Izabela Kalemba & Stanisław Dymek. (2016) Microstructure and properties of friction stir welded aluminium alloys. Welding International 30:1, pages 38-42.
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G. K. Padhy, C. S. Wu & S. Gao. (2015) Auxiliary energy assisted friction stir welding – status review. Science and Technology of Welding and Joining 20:8, pages 631-649.
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D. Li, X. Yang, L. Cui, F. He & X. Zhang. (2015) Fatigue property of stationary shoulder friction stir welded additive and non-additive T joints. Science and Technology of Welding and Joining 20:8, pages 650-654.
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L. Wan, Y. Huang, Y. Wang, S. Lv & J. Feng. (2015) Friction stir welding of aluminium hollow extrusion: weld formation and mechanical properties. Materials Science and Technology 31:12, pages 1433-1442.
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L-E. Svensson, L. Karlsson & R. Söder. (2015) Welding enabling light weight design of heavy vehicle chassis. Science and Technology of Welding and Joining 20:6, pages 473-482.
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Z. Shen, Y. Chen, J. S. C. Hou, X. Yang & A. P. Gerlich. (2015) Influence of processing parameters on microstructure and mechanical performance of refill friction stir spot welded 7075-T6 aluminium alloy. Science and Technology of Welding and Joining 20:1, pages 48-57.
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J. Shen, Y. Li, T. Zhang, D. Peng, D. Wang & N. Xu. (2015) Preheating friction stir spot welding of Mg/Al alloys in various lap configurations. Science and Technology of Welding and Joining 20:1, pages 1-10.
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G. Çam, G. İpekoğlu & H. Tarık Serindağ. (2014) Effects of use of higher strength interlayer and external cooling on properties of friction stir welded AA6061-T6 joints. Science and Technology of Welding and Joining 19:8, pages 715-720.
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A. I. Toumpis, A. M. Galloway, L. Arbaoui & N. Poletz. (2014) Thermomechanical deformation behaviour of DH36 steel during friction stir welding by experimental validation and modelling. Science and Technology of Welding and Joining 19:8, pages 653-663.
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A. De, H. K. D. H. Bhadeshia & T. DebRoy. (2014) Friction stir welding of mild steel: tool durability and steel microstructure. Materials Science and Technology 30:9, pages 1050-1056.
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J. Fallu, H. Izadi & A. P. Gerlich. (2014) Friction stir welding of co-cast aluminium clad sheet. Science and Technology of Welding and Joining 19:1, pages 9-14.
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Y. Birol & S. Kasman. (2013) Effect of welding parameters on microstructure and mechanical properties of friction stir welded EN AW 5083 H111 plates. Materials Science and Technology 29:11, pages 1354-1362.
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D He, K Yang, M Li, H Guo, N Li, R Lai & S Ye. (2013) Comparison of single and double pass friction stir welding of skin–stringer aviation aluminium alloy. Science and Technology of Welding and Joining 18:7, pages 610-615.
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Y Bozkurt, S Salman & G Çam. (2013) Effect of welding parameters on lap shear tensile properties of dissimilar friction stir spot welded AA 5754-H22/2024-T3 joints. Science and Technology of Welding and Joining 18:4, pages 337-345.
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H Izadi, J Fallu, A Abdel-Gwad, T Liyanage & A P Gerlich. (2013) Analysis of tool geometry in dissimilar Al alloy friction stir welds using optical microscopy and serial sectioning. Science and Technology of Welding and Joining 18:4, pages 307-313.
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Y Zhao, A P Wu, J L Ren, Y S Sato, H Kokawa, M Miyake & D Y Yan. (2013) Temperature and force response characteristics of friction stir welding on Invar 36 alloy. Science and Technology of Welding and Joining 18:3, pages 232-238.
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L Zhou, D Liu, K Nakata, T Tsumura, H Fujii, K Ikeuchi, Y Michishita, Y Fujiya & M Morimoto. (2012) New technique of self-refilling friction stir welding to repair keyhole. Science and Technology of Welding and Joining 17:8, pages 649-655.
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Y X Huang, L Wan, S X Lv, Z Zhang & H J Liu. (2012) New technique of in situ rolling friction stir welding. Science and Technology of Welding and Joining 17:8, pages 636-642.
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A Steuwer, D G Hattingh, M N James, U Singh & T Buslaps. (2012) Residual stresses, microstructure and tensile properties in Ti–6Al–4V friction stir welds. Science and Technology of Welding and Joining 17:7, pages 525-533.
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J Guo, P Gougeon, F Nadeau & X.-G. Chen. (2012) Joining of AA1100–16 vol.-%B4C metal matrix composite using laser welding and friction stir welding. Canadian Metallurgical Quarterly 51:3, pages 277-283.
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C Mandache, D Levesque, L Dubourg & P Gougeon. (2012) Non-destructive detection of lack of penetration defects in friction stir welds. Science and Technology of Welding and Joining 17:4, pages 295-303.
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J Taendl, S Nambu, J Inoue, N Enzinger & T Koseki. (2012) Friction stir welding of multilayered steel. Science and Technology of Welding and Joining 17:3, pages 244-253.
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C Hamilton, S Dymek & O Senkov. (2012) Characterisation of friction stir welded 7042-T6 extrusions through differential scanning calorimetry. Science and Technology of Welding and Joining 17:1, pages 42-48.
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T G Santos, R M Miranda, P Vilaça, J P Teixeira & J dos Santos. (2011) Microstructural mapping of friction stir welded AA 7075-T6 and AlMgSc alloys using electrical conductivity. Science and Technology of Welding and Joining 16:7, pages 630-635.
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Y F Sun, H Fujii, N Takaki & Y Okitsu. (2011) Novel spot friction stir welding of 6061 and 5052 Al alloys. Science and Technology of Welding and Joining 16:7, pages 605-612.
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W T Han, F R Wan, G Li, C L Dong & J H Tong. (2011) Effect of trailing heat sink on residual stresses and welding distortion in friction stir welding Al sheets. Science and Technology of Welding and Joining 16:5, pages 453-458.
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K. Kumar, SatishV. Kailas & T.S. Srivatsan. (2011) The Role of Tool Design in Influencing the Mechanism for the Formation of Friction Stir Welds in Aluminum Alloy 7020. Materials and Manufacturing Processes 26:7, pages 915-921.
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A P Gerlich & T Shibayanagi. (2011) Liquid film formation and cracking during friction stir welding. Science and Technology of Welding and Joining 16:4, pages 295-299.
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I Kalemba, S Dymek, C Hamilton & M Blicharski. (2011) Microstructure and mechanical properties of friction stir welded 7136–T76 aluminium alloy. Materials Science and Technology 27:5, pages 903-908.
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Tracie Prater. (2011) Solid-State Joining of Metal Matrix Composites: A Survey of Challenges and Potential Solutions. Materials and Manufacturing Processes 26:4, pages 636-648.
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W Woo & H Choo. (2011) Softening behaviour of friction stir welded Al 6061-T6 and Mg AZ31B alloys. Science and Technology of Welding and Joining 16:3, pages 267-272.
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G. Çam. (2011) Friction stir welded structural materials: beyond Al-alloys. International Materials Reviews 56:1, pages 1-48.
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J. G. Yang, S. H. Sung, C. S. Chen & A. H. Tan. (2011) Study of microstructural and mechanical properties of weld heat affected zones of 2024-T3 aluminium using Gleeble simulation. Materials Science and Technology 27:1, pages 357-365.
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T. Le Jolu, T. F. Morgeneyer & A. F. Gourgues-Lorenzon. (2010) Effect of joint line remnant on fatigue lifetime of friction stir welded Al–Cu–Li alloy. Science and Technology of Welding and Joining 15:8, pages 694-698.
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E. Hersent, J. H. Driver, D. Piot & C. Desrayaud. (2010) Integrated modelling of precipitation during friction stir welding of 2024-T3 aluminium alloy. Materials Science and Technology 26:11, pages 1345-1352.
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J. Altenkirch, A. Steuwer & P. J. Withers. (2010) Process–microstructure–property correlations in Al–Li AA2199 friction stir welds. Science and Technology of Welding and Joining 15:6, pages 522-527.
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A. Simar, C. Jonckheere, K. Deplus, T. Pardoen & B. de Meester. (2010) Comparing similar and dissimilar friction stir welds of 2017–6005A aluminium alloys. Science and Technology of Welding and Joining 15:3, pages 254-259.
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D. G. Richards, P. B. Prangnell, P. J. Withers, S. W. Williams, T. Nagy & S. Morgan. (2010) Efficacy of active cooling for controlling residual stresses in friction stir welds. Science and Technology of Welding and Joining 15:2, pages 156-165.
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M. Jayaraman, R. Sivasubramanian, V. Balasubramanian & S. Babu. (2009) Optimisation of friction stir welding process parameters to weld cast aluminium alloy A413 – an experimental approach. International Journal of Cast Metals Research 22:5, pages 367-373.
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H. K. D. H. Bhadeshia & T. DebRoy. (2009) Critical assessment: friction stir welding of steels. Science and Technology of Welding and Joining 14:3, pages 193-196.
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