A Review on Advancement in Friction Stir Welding Considering the Tool and Material Parameters

Welding is a fabrication process where similar or dissimilar materials can be fixed together with or without consideration of exterior heat, pressure, or filler material. For welding, whenever heat is required to fuse the surface, that process is named as fusion welding or else it is named as solid-state welding. In fusion welding, due to intense heating, mechanical behaviour of the parent material is highly influenced and distortion of the surface is very high. To overcome the conventional welding technique and improve the quality of the joint, solid-state welding processes are preferred. Among these welding processes, friction stir welding (FSW) is one of them. This joining method is unique, eco-friendly, and energy effectual which may be adopted for joining both metal and polymer-based materials. FSW uses the nonconsumable tool for fixing the workpiece, producing heat through friction between the tool and the workpiece. The automobile industry, building construction, electrical and electronic packaging, and transportation sector require a hefty amount of polymeric materials, including lightweight, excessive strength, and resistance to corrosion. The structural breakdown or material failure needs immediate repair. The present review paper focused on the joining polymer and polymer or polymer and metal material using the FSW process. Also, an in-depth review is made to improve the welding process by selecting the best tool among the various design structures of the tool probe and shoulder and their material standards. This will help in the formation of stable microstructure and enhanced mechanical strength in the weld zone.