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<p>This article provides a comprehensive overview of current practices in real-time monitoring of friction stir welding, focusing on sensor-based methodologies employed to enhance product quality and process control in this advanced joining technique. As the industrial sector moves toward Industry 4.0, the integration of sophisticated monitoring systems is essential for efficient data exchange and sustainable growth. The review discusses various critical aspects of FSW, including process parameters, while highlighting the applicability of sensors such as temperature, force, torque, acoustic emission, and imaging technologies. The study categorizes the existing sensor approaches into single-sensor and multi-sensor methodologies. The article also identifies research gaps in online defect monitoring, emphasizing the need to explore further monitoring techniques, cloud computing, and sensor fusion to facilitate the wider adoption of real-time monitoring solutions in industrial FSW applications. Through this analysis, the article aims to contribute to improving the efficiency and reliability of FSW, thereby broadening its applicability in industries like automotive and aerospace.</p>

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Real-time monitoring of friction stir welding: a review of current practices

  • 期刊论文

  • 发表日期：

    2025年7月16日

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  • Mostafa Akbari,
  • Ezatollah Hassanzadeh,
  • Hamed Savaripour

摘要

This article provides a comprehensive overview of current practices in real-time monitoring of friction stir welding, focusing on sensor-based methodologies employed to enhance product quality and process control in this advanced joining technique. As the industrial sector moves toward Industry 4.0, the integration of sophisticated monitoring systems is essential for efficient data exchange and sustainable growth. The review discusses various critical aspects of FSW, including process parameters, while highlighting the applicability of sensors such as temperature, force, torque, acoustic emission, and imaging technologies. The study categorizes the existing sensor approaches into single-sensor and multi-sensor methodologies. The article also identifies research gaps in online defect monitoring, emphasizing the need to explore further monitoring techniques, cloud computing, and sensor fusion to facilitate the wider adoption of real-time monitoring solutions in industrial FSW applications. Through this analysis, the article aims to contribute to improving the efficiency and reliability of FSW, thereby broadening its applicability in industries like automotive and aerospace.