Friction Stir Welding of Discontinuously Reinforced Aluminum Matrix Composites: A Review

Friction stir welding (FSW) is considered a promising welding technique for joining the aluminum matrix composites (AMCs) to avoid the drawbacks of the fusion welding. High joint efficiencies of 60%–100% could be obtained in the FSW joints of AMCs. However, due to the existence of hard reinforcing particles in the AMCs, the wearing of welding tool during FSW is an unavoidable problem. Moreover, the low ductility of the AMCs limits the welding process window. As the hard materials such as Ferro-Titanit alloy, cermet, and WC/Co were applied to produce the welding tools, the wearing of the tools was significantly reduced and the sound joints could be achieved at high welding speed for the AMCs with low reinforcement volume fraction. In this article, current state of understanding and development of welding tool wearing and FSW parameters of AMCs are viewed. Furthermore, the factors affecting the microstructure and mechanical properties of the joints are evaluated in detail.