Advances in friction stir welding of dissimilar aluminum and steel: a review on challenges, assisted techniques, and future prospects
Abhilash, Peerawatt Nunthavarawong, Wallop Ratanathavorn, Pruet Kowitwarangkul
Abstract
In recent years, hybrid materials combining aluminum alloys and steels have gained popularity across various industries due to their lightweight design and superior mechanical properties. However, joining these dissimilar metals is challenging because conventional fusion welding often fails due to significant metallurgical differences, leading to poor weld quality and increased defect susceptibility. Friction stir welding (FSW) has emerged as a promising technique to address these issues. This article reviews recent advancements in FSW of aluminum alloy and steel components, focusing on aerospace, marine, and automotive applications. It examines the impact of FSW parameters on intermetallic compound development and dissimilar weld joint characteristics. Topics include interlayer applications, modified FSW procedures, and numerical simulations predicting flow behavior, temperature profiles, and residual stresses. The study aims to be a valuable resource for professionals and researchers seeking to improve the joining of high-performance materials in key industries.