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Review
Review on friction stir welding of magnesium alloys
Kulwant Singh a,∗, Gurbhinder Singh b, Harmeet Singh a
a I. K. Gujral Punjab Technical University, Kapurthala, Punjab, India
b Guru Kashi University, Talwandi Sabo, Punjab, India
Received 16 May 2018; received in revised form 27 June 2018; accepted 28 June 2018
Available online 18 July 2018
Abstract
Friction Stir Welding (FSW) is considered to be the most significant development in metal joining in last two decades. FSW has many
advantages when welding magnesium or lightweight alloys. The Friction stir welding of magnesium alloy has many potential applications
in major industries i.e. land transportation, aerospace, railway, shipbuilding and marine, construction, and many other industrial applications.
Even magnesium alloys have been used in industrial equipment of nuclear energy as magnesium alloys have low tendency to absorb neutrons,
sufficient resistance to carbon dioxide and excellent thermal conductivity. Recently, the research and development in FSW field and associated
technologies have been developing rapidly worldwide. In this review article, the basic principle of friction stir welding and several aspects
of friction stir welded magnesium alloys have been described. The current state of friction stir welding of magnesium alloys is summarized.
In spite of this, much remains to be learned about the process and opportunities for further research are identified.
© 2018 Published by Elsevier B.V. on behalf of Chongqing University.
This is an open access article under the CC BY-NC-ND license. (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review under responsibility of Chongqing University
Table 2
Advantages/Benefits of friction stir welding over others joining processes [32,45].
Fig. 3. (a) Shoulder shapes and surface features, (b) FSW tool probes, and (c) Friction stir welding tools designed at TWI [54].
2.2. Welding parameters along the line of joint [75]. The rotation of tool results in stir-
ring and mixing of material around the rotating pin and the
In friction stir welding process, there are two important translation of tool moves the stirred material from the front to
parameters: (i) tool rotation rate (rpm) in clockwise or coun- the back of the pin and finishes welding process [76]. Lee W.
terclockwise direction and (ii) tool traverse speed (mm/min) et al. [77] studied the effect of different friction stir welding
Table 3
Summary of tool materials, geometries and welding variables used for FSW of several magnesium alloys.
Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference
AZ31 Magnesium Tool steel Concave Shoulder diameter - 15 mm Pin Tool Rotational Speed- 2000 rpm Crack propagation [96]
alloy length - 3.7 mm (M5 threaded) Tool Welding Speed-200 mm/min was influenced by the
tilting angle - 3° “onion-ring structure”
of the stir zone
AZ31 Magnesium H13 tool steel Conical pin Shoulder diameter −18 mm Pin Tool Rotational Speed-800 to Superior [103]
alloy height −7.8 mm Pin diameter - 9 & 1600 rpm Welding comprehensive
6 mm, Tool tilt angle −2.5° Speed-120 mm/min mechanical
performance of the
FSW joints has been
achieved at a
403
404
Table 3 (continued)
Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference
AZ31B Magnesium Tool Shoulder made Screw tip geometry Shoulder diameter - 25 mm Probe Tool Rotational Speed-1500 to Tensile strength value [108]
alloy of AISI 1040 steel, diameter - 5 mm Pin length - 4 mm 2300 rpm Welding speed - 100 to of joints observed
Tool screw tip made 190 mm/min lower than the tensile
of HSS steel. strength value of the
base material.
AZ31B-H24 Mg H13 steel tool Scrolled left-hand threaded pin Shoulder diameter - 19.05 mm Pin Welding Speed-10 mm/s or 20 mm/s. The hardness [93]
alloy (Lap Joint) (46.6–50 HRC) diameter - 6.35 mm Pin length - Tool Rotational Speed- 1000 rpm decreased from the
2.75 mm Tilt angle - 0.5° and 1500 rpm base metal to the stir
zone across the
heat-affected zone
Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference
AZ31B-O Mg alloy High Carbon High Cylindrical pin with Left hand Shoulder diameters - 18 mm and Tool Rotational Speed-1200 & Tensile strength [95]
Chromium Steel thread 1 mm (pitch) 20 mm Pin diameter- 7 mm Pin 1950 rpm Welding speed −40 & increases with
length - 4.8 mm D/d ratio of tool - 60 mm/min increase in the value
2.56 and 3 of weld pitch. high
tensile strength of
187.8 N/mm2 (91%
of base material) was
achieved at high weld
pitch of 0.050 mm/rev
with tool shoulder
diameter of 20 mm
AZ61 Mg alloy SKD61 steel (48–50 Concave (M4 thread) Shoulder diameter - 12 mm Pin Tool Rotational Speed-1250 & Strength of an FSSW [100]
405
(continued on next page)
406
Table 3 (continued)
Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference
AZ 91 Magnesium HCHCr D2 grade (60 Threaded straight cylindrical pin, Shoulder diameters - 18 mm Pin Tool Rotational Speed-710 to High tensile strength [63]
Alloy to61 HRC) Tapper cylindrical pin, Straight diameter- 6 mm Pin length - 5.8 mm 1400 rpm Welding Speed - 28 to obtained with
cylindrical pin 56 mm/min threaded straight
Fig. 4. Joint configuration (a) Square butt joint [92] (b) Overlapped joint [93].
parameters on the mechanical properties of AZ31B-H24 mag- friction stir welds of aluminium alloys and found that the
nesium alloy joints and reported that joint strength increased material flow patterns are highly dependent upon the axial
with increasing tool rotation speed and decreasing welding force. Padmanaban et al. [86] studied the effect of axial force
speed, whereas Lim et al. [78] found no significant effect on mechanical properties of AZ31B magnesium alloy joints
of processing parameters on the tensile strength of friction fabricated by friction stir welding. They found that when the
stir welded AZ31B-H24 alloy. In addition to the tool rotation axial force was relatively low, there was a possibility of in-
speed and traverse speed, some another process parameters sufficient stirring at the bottom but with higher axial force,
are the angle of spindle or tool tilt with respect to the work- the weld was sound. It showed that sufficient axial force was
piece surface, target depth and axial force [79–81]. A suit- required to form good weld because the temperature during
able tool tilt towards trailing direction ensures that the tool friction stir welding defined the amount of plasticized mate-
shoulder holds the stirred material and move material effi- rial and the temperature was highly dependent on the axial
ciently from the front side of the pin to the back of the pin force.
[82]. The insertion/target depth of the tool pin into the work-
pieces is also an important factor for producing sound welds. 2.3. Joint configuration
The target depth of pin is related to the tool pin height. The
tool shoulder face always kept in contact with the surface The most suitable joint configurations for friction stir weld-
of workpiece to move the stirred material effectively to pro- ing are butt and lap joints. A simple square butt joint and lap
duce solid state joint. This can be done by proper selection joint are shown in Fig. 4. Two sheets of the workpiece with
of the insertion/target depth of the tool pin. Bahari [83] re- same thickness are placed together and properly clamped to
ported that the insertion depth should not be too shallow or avoid the abutting the joint faces from being forced apart dur-
too deep. In the case when it is of very little depth, the tool ing the process. During the initial plunge of the FSW tool, the
shoulder does not contact the original workpiece surface and forces are large so additional care is required to ensure the
cannot move the stirred material efficiently which resulted in position of plates as reported by Padmanaban et al. [52]. The
the generation of welds with inner channel/surface groove. rotating FSW tool is plunged into the joint line and traversed
And when the insertion depth is too deep, the tool shoulder along the line when the shoulder of the tool is in intimate con-
plunges into the workpiece producing excessive flash. Ouyang tact with the surface of the plates, produced a weld. [87–88].
et al. [84] reported that during friction stir welded AA6061 In case of lap joint, two lapped sheets are clamped on a
alloy, the shoulder force that was directly responsible for the backing plate. A rotating tool is vertically plunged through
plunge depth of the tool pin into the surface of the workpiece the upper plate and into the lower plate and traversed along
during the plungement. The material flow patterns highly de- the desired direction, joined the two plates [89]. Many other
pended upon the geometry of the threaded tool, welding tem- configurations can be produced by the combination of butt
perature, material flow stress and axial force. Krishnan et al. and lap joints. Some other types of joint designs Fig. 5 (edge
[85] studied the mechanism of onion ring formation in the butt joint, T butt joint, multiple lap joint, T lap joint, and fillet
408 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
Table 4
Summary of substrate materials, tool geometries, welding parameters and grain size of FSW Mg alloys.
Work piece Plate Thickness Tool Geometry Rotational Speed Welding Speed Grain Size μm Reference
material
AZ31 Mg alloy 8 mm Conical threaded 800–1600 rpm 120 mm/min 6–20 [103]
AZ31 Mg alloy 6 mm Cylindrical threaded 1600 rpm 600 mm/min 9.8 [133]
AZ31–O Mg 2 mm Concave shoulder, threaded 600–1400 rpm 200–2000 mm/min 1.66–5.15 [97]
alloy tool pin
AZ31B Mg alloy 6 mm Straight cylindrical, Tapered 1600 rpm 0.67 mm/s 6.3–11.1 [52]
cylindrical, Threaded
cylindrical, Triangular and
Square
AZ31B-H24 Mg 2 mm Left-hand thread and 1000–2000 rpm 5–30 mm/s 5.4 ± 2.2 [129]
alloy right-hand thread
AZ31B-H24 Mg 4.95 mm – 1000 rpm 2 and 4 mm/s 9 [130]
alloy
AZ31B-H24 Mg 4.95 mm – 500–1000 rpm 1–4 mm/s 8.5–9.3 [131]
Alloy
AZ31B-H24 Mg 2 mm Scrolled shoulder 1000 rpm and 10 mm/s or 20 mm/s 7.4–9.5 [37]
alloy 1500 rpm
AZ31B-H24 Mg 2 mm Scrolled shoulder, 2000 rpm 5 - 30 mm/s 3.7–5.5 [106]
alloy Cylindrical threaded
AZ31B-O Mg 5 mm Left hand threaded tool pin 1200–1950 rpm 40–60 mm/min 9 [95]
alloy
ZK60 and AZ31 6 mm Cylindrical threaded 800 rpm 100 mm/min 8.7 (AZ31 side) [134]
Mg alloys and 2.7 (ZK60
side)
AZ31 and AZ91 3 mm Tapered pin 1400–1800 rpm 25–100 mm/min 6.5 ± 6.8 [94]
Mg alloys
AZ91 Mg alloy 5 mm Cylindrical, Triangle, Square 710–1400 rpm 12.5–63 mm/min 9–32 [135]
AZ91 Mg alloy 3 mm – 100–1400 rpm 80–200 mm/min 2 [114]
AZ91 with CaO 4 mm – 1250 rpm 32 mm/min 1–2 [128]
AZ91C Mg alloy 8 mm Square pin 800–1600 rpm 40 mm/ min 14 (FSW) and 8 [105]
(SFSW)
AZ91D Mg alloy 3 mm Tapered cylindrical threaded 1025–1525 rpm 25–75 mm/min 7–21 [104]
AZ91D Mg alloy 4 mm – 115 - 377 rad/s 32 and 187 mm/min 7–19 [132]
orientations arising from the FSW process has been becom- stirred magnesium alloys [114,131,137,149,172,176,180,181].
ing an emerging research area of interest. For FSW of Mg Chowdhury et al. [109] reported that AZ31B-H24 Mg alloy
alloys, the local texture developed in the joints due to the contained a strong crystallographic texture with basal planes
critical material flow driven by the rotating tool which affect (0002) largely parallel to the rolling sheet surface and ˂112̅0˃
the mechanical performance. Some research reported that the directions aligned in the rolling direction (RD). But, After
initial texture not much affected the final microstructure and FSW the basal planes in the SZ were slightly tilted toward
texture in the nugget zone (NZ) [168], different texture dis- the TD determined from the sheet normal direction (i.e. top
tributions formed in the thermo-mechanically affected zone surface) and also slightly inclined toward the RD determined
(TMAZ) exerts an influence on the mechanical and fracture from the transverse direction (i.e. cross section) due to the
behavior of the joint [169]. Some texture studies of FSW mag- intense shear plastic flow near the tool pin surface. The pris-
nesium alloys have been reported [109,131,137,149,168–181]. matic planes (101̅0) and pyramidal planes (101̅1) formed fiber
Mironov et al. [96] reported that the AZ31 Mg alloy base textures. Yang et al. [170] reported that during FSW of Mg–
material had a bimodal microstructure consisting of relatively 3Al–1 Zn alloy, the shoulder size did not influence the texture
coarse elongated grains and a minor fraction offine equiaxed modification induced by FSW in the nugget and weaken the
grains. They found that some of the coarse grains contained {0002} texture in the TMAZ so that fracture was occurred
lenticular-shaped {101̅2} twins presumably originating from in the nugget. Commin et al. [137] reported that AZ31 hot
the prior hot extrusion. The texture was dominated by a mod- rolled base metal, the {0002} basal plane normal was par-
erate {hkil} < 1210> fiber orientation . In the stir zone, allel to the sample normal direction. The shoulder diameter
significant grain refinement took place and the {0001} < 13 mm did not induce such large modification and the frac-
uwtv > B-fiber texture became predominant. The microstruc- ture was located in the TMAZ but in the 10 mm shoulder
ture and texture of the base material and the material in the diameter sample, the strong {0002} texture was modified by
central part of the stir zone, higher-resolution EBSD maps the welding process. The basal plane progressively oriented
and (0001) and (112̅0) pole figures are shown in Fig. 7. The perpendicular to the welding direction when approaching the
formation of this texture is also typically reported in friction- nugget zone. Liu et al. [133] reported that sudden change of
410 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
Fig. 7. EBSD orientation maps and 0001and 11̅20 pole figures illustrating microstructure and texture in (a) base material, and (b) central part of stir zone
[96].
texture at the stir zone (SZ)/transition zone (TZ) interface and increasing the shoulder size resulted in a higher heat input
different twinning action between the TZ and SZ-side have an and therefore a thermal expansion mismatch reduction during
impact on fracture behavior of bending samples. The effect of cooling. Ahmed and Krishnan [138] reported that high-level
textural variation on fracture behavior in bending is highly de- residual stresses can occur in weldment due to restraint by
pendent on the local stress state. Park et al. [149] reported that the parent metal during weld solidification. The stresses may
the heterogeneous basal plane texture in friction-stir-welded be as high as the yield strength of the material itself. When
AZ61 Mg alloy in the fracture region caused the preferen- combined with normal load stresses these may exceed the de-
tial plastic deformation and eventually. Here, the major issue sign stresses. The removal of residual stresses takes place due
to recognize is the nucleation of new grains and continuous to the fact that the thermal energy received by the metal al-
deformation influence the final texture of the material joint lows for grain boundary sliding and removal of metallurgical
during FSW. It is essential to distinct the effect of the de- defects like dislocations, vacancies and slip planes. The exist-
formation by tool shoulder through the forging action when ing literature showed that the residual stresses induced during
the tool pin has passed. The deformation under tool shoulder the welding process of materials. In FSW, residual tensile
is expected to influence the final texture considerably and it stress peaks are observed in the TMAZ in the longitudinal
enhances a shear deformation component to the recrystallized direction and compressive residual stress peaks occured in a
volume processed by the tool pin at lower temperature. transversal direction in the fusion zone (FZ) or nugget zone.
Kouadri-Henni et al. [139] reported that the FSW process
5. Residual stresses highly modified the distribution of residual stress in the differ-
ent zones. The HAZ has weak compressive residual stresses
Although FSW is a solid-state joining process which pro- and TMAZ and FZ the residual stresses are tensile in na-
duces low-distortion welds of high quality, significant levels ture. The residual stress profile in TMAZ and FZ showed
of residual stresses can be present in the weld after fabrication two noticeable peaks in the TMAZ whereas the centre of the
[136]. Commin et al. [97] reported that the magnesium alloy FSW has very low tensile residual stresses. Additionally, the
usage has been limited due to its active chemical properties, profile was partially non-symmetrical transversal to the weld
high coefficient of thermal conductivity, low melting point, and the TMAZ has not the same behaviour on the advancing
hot cracking sensitivity, coarse grains and complex resid- side and the retreating side of the weld. The advancing side
ual stresses in the weld seam after welding. Commin et al. of the weld has a higher level of residual stress in compar-
[137] studied the influence of the microstructural changes ison with the retreating side. Yan et al. [140] reported that
and induced residual stresses on tensile properties of wrought there are many methods to improve the mechanical proper-
magnesium alloy friction stir welds and showed that the high- ties of welded joints such as to select the appropriate welding
est tensile residual stresses were obtained in the TMAZ. The method, to select the appropriate welding parameters, and to
larger tool shoulder led to reducing residual stresses. Actually, control the penetration ratio and the correct choice of post
K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416 411
weld heat treatment. Post-weld heat treatment is an effective non-heat-treatable (solid-solution-hardened). So the hardness
way to eliminate the residual stress and to restore the prop- of the magnesium alloy varies with the variation in aluminium
erty of the welded joints of magnesium alloys and improve fraction in it. It has been also reported that hardness profile af-
the performance of the joints [141]. fected by precipitate distribution and/or rather than grain size
in the weld. The hardness value decreased gradually from
6. Mechanical properties about 73 HV to approximately 63 HV in the center of the
SZ through the HAZ and TMAZ of the joints. The presence
The existing literature of FSW reports that the friction of the lowest hardness in the SZ attributed to the dynamic
stir welding results in significant microstructural development recrystallization and grain growth. The decrease in the hard-
within the stir zone as well as in TMAZ and HAZ. This vari- ness was due to the larger grain size at the higher rotational
ation affects the post-welding mechanical properties. There- rate [129]. Zhang et al. [147] and Xie et al. [148] reported
fore, the mechanical properties are reviewed here and are that during FSW of Mg–Al–Ca and Mg–Zn–Y–Zr magnesium
summarized in Table 5. alloys, large intermetallic compounds (Al2 Ca and Mg–Zn–Y
phases) were broken up and dispersed in the nugget zone, re-
6.1. Tensile properties sulted in the significant increase in hardness. So, the hardness
in the nugget/stir zone was substantially higher than the other
As reported earlier that joint strength increased with in- zones. But, Park et al. [149] reported that the uniform hard-
creasing tool rotation speed and decreasing welding speed ness throughout various zones of the weld of FSW AZ61.
[77], but Lim et al. [78] found no significant effect of pro- Esparza et al. [150] also found that FSW AM60 weld ex-
cessing parameters on the tensile strength of friction stir hibited almost similar hardness across the whole weld. Xie
welded AZ31B-H24 alloy. Pareek et al. [142] studied FSW et al. [151] reported that ZK60 is a precipitation strength-
of AZ31B-H24 magnesium alloy and showed that the tensile ening magnesium alloy and the MgZn2 precipitates in ZK60
strength increases with increasing rotational speed. Park et al. magnesium alloy is much finer than Al12 Mg17 particles in AZ
[143] also studied FSW on AZ31Mg alloy plates at tool rota- and AM system alloys. So, the hardness of the ZK60 alloy
tion speed 1230 rpm and transverse speed 90 mm/min which is mostly governed by the precipitates. The hardness values
showed lower yield strength and elongation, and slightly within the nugget zone of the as-welded joint found signifi-
lower ultimate tensile strength (UTS) of the weld. Nakata cantly lower than those of the base metal and other zones due
et al. [144] studied the optimal processing conditions for FSW to the further dissolution of MgZn2 particles during FSW pro-
of AZ91D Mg alloy sheet. The higher tensile strength in cess. In such cases, the precipitate is the dominant factor to
the weld was obtained than base material with a rotational govern the hardness of the nugget zone rather than the grain
speed between 1240 rpm to 1750 rpm and transverse speed of size. Singarapu et al. [47] reported that increasing the rota-
50 mm/min. Padmanabham et al. [52] studied the tool mate- tional speed increases the microhardness and then gradually
rial effect on the friction stir welding of AZ31B magnesium decreases. They stated two reasons for the improved hardness
alloy. Different tool materials such as stainless steel, high- of stir zone. (i) the grain size of stir zone is much finer than
speed steel, and armour steel, mild steel and high carbon the base metal, grain refinement plays a significant role in
steel were used. It was concluded that the joints fabricated material strengthening. (ii) the small particles of intermetal-
by high carbon steel tool with 66 HRC, threaded pin profile lic compounds are also a benefit to hardness improvement.
and a shoulder diameter of 18 mm exhibited superior tensile Further increasing the rotational speed decreases the micro-
properties. Chowdhury et al. [109] reported the strength and hardness due to the high heat generation which causes ma-
ductility of the AZ31B-H24 Mg alloy after FSW decreased terial softening and resulted in a decrease in the microhard-
at all the strain rates, with a joint efficiency lying in-between ness. They reported that the softening of the nugget/stir zone
about 75 and 82%. A minor increase of yield strength and was the result of coarsening and/or dissolution of strength-
ultimate tensile strength with increasing strain rate was ob- ening precipitates. Sunil et al. [94] studied the joining of
served, while the ductility in the base alloy decreased consid- AZ31 and AZ91 Mg alloys by friction stir welding. They
erably. After FSW the strain rate dependence of the tensile reported that a gradual increase in the hardness from AZ31
properties nearly disappeared within the experimental scatter. base material to AZ91 base material. In the nugget/stir zone,
large variations in the hardness values found due to the com-
6.2. Hardness bined effect of fine grain structure and the presence of hard
Mg17 Al12 phase along with some regions of AZ31. Solid so-
As reported earlier that most commercial magnesium al- lution strengthening also contributed toward an increase of
loys are ternary in nature and made up of aluminium, zinc, hardness as the nugget zone becomes a supersaturated solid
thorium and rare earth. In ternary Mg-Al series, aluminium solution due to the dissolution of more aluminium by reduced
is the main alloying element which involves AZ (Mg–Al– Mg17 Al12 phase. They concluded that the increased hardness
Zn), AM (Mg–Al–Mn) and AS (Mg–Al–Si) alloys [13,14]. in the nugget zone can be attributed to the grain refinement
Mishra and Ma [32], Dickerson et al. [145] and Uematsu et al. and the presence of Mg17 Al12 particles along with solid so-
[146] reported in literature that aluminum alloys are of two lution strengthening. Kouadri-Henni et al. [114] reported that
types: (i) heat-treatable (precipitation-hardenable) alloys, (ii) the significant variations (increase or decrease) of microhard-
412
Table 5
The summarized mechanical properties of FSW Magnesium alloys.
ness measured in each transition region i.e. BM and HAZ, axial force, insertion depth), in addition to the tool rota-
HAZ and TMAZ, TMAZ and nugget/stir. The microhardness tion speed and traverse speed, plays an important role in
in the HAZ, near to the TMAZ zone, is the same as the base producing sound welds. The material flow patterns highly
metal and sometimes slightly higher. The presence of pre- depended upon the geometry of the tool pin, welding tem-
cipitates formed in this zone responsible for augmenting the perature, material flow stress and axial force. The welding
microhardness. The microhardness in the TMAZ and in the temperature is dependent on the axial force.
nugget/stir is lower than in the base metal, even though the 3. There is a lot of scope for research because the joint de-
size of the grains was smaller than the base metal. They ex- signs like- edge butt joint, T butt joint, multiple lap joint,
plained that microhardness decreases due to the influence of T lap joint, and fillet joint apart from the butt and lap
the dislocation density, residual stress variations in the weld configurations are also useful in many applications.
and existence of the crystallographic texture. This difference 4. FSW modified the microstructure of the base metal and
in microstructure explained by the reduction in the number resulted in the formation of weld stir zone (SZ), thermo-
of precipitates which leads toward a reduction in the micro- mechanically affected zone (TMAZ) and heat affected zone
hardness. (HAZ). Each zone exhibits different microstructural char-
acteristics, including grain size, dislocation density, and
7. Applications residual stress as well as precipitate size and distribution.
5. During the FSW process, the plastic deformation in the
The applications of FSW as well as magnesium material occurs at the elevated temperatures and prefer-
alloy has been reported in earlier published litera- ential orientation/texture evolution is possible in SZ and
ture [6,19,21,23,34,35,40,41,45,47,52,63,74,92–95,97– TMAZ. The texture affects the mechanical properties of
99,101–103,105,106,108,109,114,128,129,131,132,134– the material.
135,137,139,149,152,155–181] as summarized below: 6. The significant level of residual stresses produced due to
the large deformation during FSW process. The advancing
1. Land Transportation: Engine chassis, wheel rims. Track side of the weld has a higher level of residual stress in
bodies, tail lifts for tracks, mobile cranes, body frames, comparison with the retreating side. The HAZ has weak
fuel tankers. compressive residual stresses and the residual stresses are
2. Aerospace Industry: Fuel tanks, wings, fuselages, cryo- tensile in nature in TMAZ and FZ.
genic tank for space vehicles, aviation fuel tanks. 7. The mechanical properties are highly influenced by the
3. Railway Industry: Goods wagons, container bodies, under- FSW parameters and conditions. The increase in hardness
ground carriages and trams. in the nugget/stir zone is dependent on the grain refinement
4. Shipbuilding and Marine Industries: Panels for decks and as well as the presence of Mg17 Al12 particles along with
floors, helicopter platforms, hulls and superstructures, ma- solid solution strengthening.
rine and transport structures, offshore accommodation, 8. The friction stir welding of magnesium alloy has a wide
masts and booms for sailing boats. range of applications in land transportation, aerospace, rail-
5. Construction Industry: Bridges, frames, pipelines, reactors way, shipbuilding and marine, construction and many other
for power plants. industries.
6. Other Industry Sectors: Refrigeration panels, Motor hous-
ing.
9. Future outlook
8. Concluding remarks
1. The mostly different tool is used by individual researchers
In this review article current development in FSW process, and the only inadequate information is available in existing
microstructure, residual stresses, mechanical properties, and literature. Earlier published literature reported that a cylin-
applications of friction stir welding of Mg alloys have been drical threaded pin with concave shoulder tool features is
addressed. The basic conclusions that can be drawn from this widely used for FSW. But many special profile tools have
review article are as follows: also developed which needs to justify.
2. FSW process parameters (tool rotational speed, tool tra-
1. Tool geometry is the most influential part of FSW process verse speed, tool tilt angle, axial force, and target depth)
development. The tool pin profile, shoulder diameter and are important to produce sound and defect-free weld joint.
tool material highly influenced the joint quality. The fric- The selection criterion of these parameters needs to gen-
tion between the tool shoulder and workpiece is the major eralize.
component of heating. So, the size of pin and shoulder is 3. Generally, butt and lap joint configuration have been
more important than the design features of the tool. The choosing for FSW as reported in published work. But, for
scrolled shoulder surface also played a significant role in the real implementation of the FSW, researchers need to
stirring/blending the material. be work on other joint designs.
2. The FSW process parameter (angle of spindle or tool tilt 4. The material flow is the very complex phenomenon and
with respect to the workpiece surface, target depth and still requires more understanding.
414 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
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