Friction stir welding optimization techniques: A review

Friction stir welding (FSW) is a relatively new solid state joining process. The increasing use of aluminum alloys in aviation, marine and transport industries gives rise the development of new solid state joining process. This paper reviews the recent development in the friction stir welding, microstructure of friction stir welding joint and the effect of friction stir welding parameters on the mechanical properties of the joints. The development of the sound joints between dissimilar materials is of great importance in many emerging applications. In this review article more emphasis has been given to dissimilar welding of different series of aluminum alloy. Different optimization techniques has been reviewed for excellent friction stir welding joints efficiency. Application of Taguchi, Grey Relation Analysis, Particle Swarn Analysis and Response Surface Methodology in friction stir welding has been reviewed. In addition, several important key problems and issues remain to be addressed about the optimization of friction stir welding and opportunities for further research are identified.