Frontiers in Friction Stir Welding: Processing, Microstructure and Modelling

Dear Colleagues,

The last three decades have seen significant developments in friction stir welding. Many additional derivative processes (friction extrusion, friction consolidation, friction forging, friction riveting, friction stir cladding, friction Stir additives, etc.) have been developed and are able to offer an energy efficient method through which similar and dissimilar materials can be processed/joined while avoiding melting and achieving superior microstructural characteristics that are not possible by conventional means. FSW has emerged as a reliable method to join different grades of similar and dissimilar aluminum alloys. FSW has also been used to effectively join magnesium, copper, dissimilar metals (such as aluminum to steel, magnesium to steel, copper to steel, etc.), high-temperature alloys (Ti alloys, steels, nickel superalloys, high-entropy alloys, etc.), and non-metallic thermoplastic polymers. Innovations in tool design, the development of control methods such as force control, temperature control, and power control, etc., and the adoption of robotic arms have enabled high-speed friction stir welding to match industry expectations and to move towards the adoption of this process. Our understanding of the process parameters and corresponding process response, plastic deformation, tool design, material flow, and thermal boundary conditions has expanded over the years, resulting in superior microstructures and mechanical performance. Computational modelling (FEM, crystal plasticity, SPH, etc.) and in situ microscopy (SEM, EBSD, TEM, APT, etc.) have provided new insights into the complex plastic deformation phenomena and microstructural transformations that take place during FSW.

This  Special Issue of Materials aims to bring together a collection of both original research and review publications that introduce key insights that have been gained by both experimental and computational methods and microstructural characterization on the topic of friction stir welding and allied solid phase joining processes.

Dr. Hrishikesh Das
Dr. Piyush Upadhyay
Guest Editors

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• friction stir welding
• friction stir processing
• friction riveting
• stationary shoulder friction stir welding
• friction extrusion
• friction consolidation
• friction stir additive manufacturing
• friction stir/refill friction stir spot welding
• robotic friction stir welding
• control system
• modelling/simulation
• microstructure evolution
• mechanical performance