Friction Stir Welding for Aerospace Alloys

Friction stir welding (FSW) has gained prominence as a transformative welding technique, especially for aerospace alloys, owing to its inherent advantages over conventional fusion welding methods. FSW offers distinct advantages, including minimized thermal distortion, improved mechanical properties, and a reduced heat-affected zone, addressing the challenges posed by traditional welding methods. Focused primarily on metals alloys and composites, this study explores the main process parameters, tool materials, and design considerations, critical for achieving superior weld quality and mechanical performance. This chapter investigates into the microstructural evolution during FSW, emphasizing the impact of welding parameters on grain refinement and defect mitigation. The study also discusses recent advancements in tool design and process optimization techniques to enhance the efficiency and reproducibility of FSW in aerospace manufacturing.