Recent advances in joining technologies of aluminum alloys: a review

Aluminum alloys have become vital in industries such as aerospace and automotive due to their high strength-to-weight ratio, corrosion resistance, and versatility. This study examines traditional joining methods like welding, brazing, and mechanical fastening, alongside modern innovations such as friction stir welding (FSW), laser beam welding (LBW), and hybrid laser arc welding (HLAW). These techniques enhance aluminium alloys' mechanical performance and structural integrity, addressing challenges like hydrogen embrittlement and environmental concerns associated with hexavalent chromium. It discusses recent efforts to improve fatigue resistance, fracture toughness, and thermal stability, emphasizing the role of advanced alloys in meeting industry demands. The study concludes by identifying future research directions in alloy design, sustainable manufacturing practices, and the integration of emerging technologies to optimize aluminum alloys for next-generation applications.