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Review

A Review of Friction Stir Welding of Industrial Alloys: Tool Design and Process Parameters

by
Vincenzo Lunetto
1,2,*,
Manuela De Maddis
1,2,
Franco Lombardi
1,2 and
Pasquale Russo Spena
1,2
1
Department of Management and Production Engineering, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
2
Advanced Joining Technologies Center (J-Tech@PoliTO), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
*
Author to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2025, 9(2), 36; https://doi.org/10.3390/jmmp9020036
Submission received: 25 December 2024 / Revised: 17 January 2025 / Accepted: 21 January 2025 / Published: 28 January 2025
(This article belongs to the Special Issue Advances in Welding Technology)
Versions Notes

Abstract

Friction stir welding (FSW) is a pivotal technology with ongoing relevance across industries. Renowned for its ability to join materials with dissimilar melting points while mitigating thermal distortions, FSW offers relevant advantages over traditional fusion welding. However, the adoption of FSW for high-strength alloys poses notable challenges, including: (i) accelerated tool wear, (ii) the need for special tool features tailored to these alloys, and (iii) a narrow process window. This review provides a comprehensive overview of FSW as an advanced technique for joining metal alloys for several industrial fields. Emphasis is on materials such as Mg-, Cu-, Ti-, and Ni-based alloys, automotive steels, stainless steels, and maraging steels. The research highlights the critical influence of tool design—main dimensions, features, and materials—and process parameters—rotational and welding speeds, tilt angle, and plunge depth or vertical load—also considering their influences on defect formation. Detailed insights are provided into material flow and the formation of the different weld regions, including SZ, TMAZ, and HAZ.
Keywords: friction stir welding; solid-state welding; process parameters; tool design; material flow; microstructural evolution; mechanical properties; weld defect friction stir welding; solid-state welding; process parameters; tool design; material flow; microstructural evolution; mechanical properties; weld defect

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MDPI and ACS Style

Lunetto, V.; De Maddis, M.; Lombardi, F.; Russo Spena, P. A Review of Friction Stir Welding of Industrial Alloys: Tool Design and Process Parameters. J. Manuf. Mater. Process. 2025, 9, 36. https://doi.org/10.3390/jmmp9020036

AMA Style

Lunetto V, De Maddis M, Lombardi F, Russo Spena P. A Review of Friction Stir Welding of Industrial Alloys: Tool Design and Process Parameters. Journal of Manufacturing and Materials Processing. 2025; 9(2):36. https://doi.org/10.3390/jmmp9020036

Chicago/Turabian Style

Lunetto, Vincenzo, Manuela De Maddis, Franco Lombardi, and Pasquale Russo Spena. 2025. "A Review of Friction Stir Welding of Industrial Alloys: Tool Design and Process Parameters" Journal of Manufacturing and Materials Processing 9, no. 2: 36. https://doi.org/10.3390/jmmp9020036

APA Style

Lunetto, V., De Maddis, M., Lombardi, F., & Russo Spena, P. (2025). A Review of Friction Stir Welding of Industrial Alloys: Tool Design and Process Parameters. Journal of Manufacturing and Materials Processing, 9(2), 36. https://doi.org/10.3390/jmmp9020036

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