The solid-state welding method known as friction stir welding (FSW) bonds two metallic work parts, whether the same or different, by plastically deforming the base metal. The frictional resistance between both metallic work pieces causes them to produce heat, which produces plastic deformation and welds them. However, the weldability and strength of FSW joints mainly depend on the FSW parameters. This review work highlights the previous research work on the FSW parameters and their effects on the weldability and quality of the aluminum alloys joined with similar and dissimilar metals through the FSW method. About 150 research studies were systematically reviewed, and the articles included data from peer-reviewed journals. It has been concluded that the key parameters, including welding speed, “rotational speed”, “plunge depth”, “spindle torque”, “shoulder design”, “base material”, “pin profile” and “tool type", significantly affect the weldability of the aluminum joint through the FSW method. Also, the selection of these parameters is important and fundamental as they directly affect the joint. It is recommended that future work focus on FSW for aluminum. Among these, the most essential is the application of artificial intelligence (AI) techniques to select the optimum FSW parameters for aluminum welding.

Joining of aluminium alloys to steels has been extensively studied, especially in the automotive sector. However, aluminium alloys are known to be difficult to join with steels when methods involving fusion welding are used because of hot cracking problem. Hence, a high strength joint between these dissimilar metals would be of benefit especially in reducing the weight of products. In this work the torch brazing method was applied to join AR500 steel with AA7075 aluminium alloy using Al-Si-Zn base filler metal at various flame times. The effect of the brazing work on the intermetallic phase formation and the mechanical strength of the joints were investigated. In this work, the maximum shear load obtained was 6460 N and the presence of the intermetallic phases had reduced the shear strength of the brazed joints. However, the torch brazing process using Al-Si-Zn filler metal had successfully facilitated the joining of these dissimilar metals.

The present study utilizes a metal inert gas welding (MIG) to make a dissimilar weld joint of different stainless steel grades AISI 304, 314, 316L, 420 and a standard structural steel S355MC to estimate the correlation of a microstructure and the mechanical properties. The microstructure of the base metals (BM), the heat affected zone (HAZ), the fusion zone (FZ) and the weld seam were analyzed using optical microscopy. Optical microscopy did not reveal any presence of weld defects such as porosity or cracks. The analysis of microstructure showed that both the austenitic and martensitic stainless steel weld structures contain some retained delta ferrite and coarse Me23C6 carbides in the HAZ, while the FZ exhibits delta ferrite and some retained austenite. The hardness profiles revealed difference between austenitic and martensitic steel welds that the later showed extremely high values in the HAZ (~500 HV/0.1) which causes fracture in this zone. The welds of all austenitic steel grades withstood tensile test, showing the average tensile strength of 472 MPa with fracture observed in the base metal zone. It made clear that the use of a filler rod 308LSI is suitable only for the austenitic stainless and structural steel dissimilar welds, and not appropriate for martensitic-structural steel welds. The achieved results revealed that the higher hardness of the martensitic phase in the HAZ of AISI 420 is closely related with the formation of untempered coarse martensitic structure and higher carbon content.

Welding of dissimilar aluminium alloys has been a challenge for a long period until the discovery of the solid state welding technique called friction stir welding (FSW). The discovery of this technique encouraged different research interests revolving around the optimization of this technique. This involves the welding parameters optimization and this optimization is categorized into two classes i.e. similar alloys and dissimilar alloys. This paper reports about the mechanical properties of the friction stir welded dissimilar AA1050-H14 and AA5083-H111 joint. The main focus is to compare the mechanical properties of specimens extracted from different locations of the welds i.e. the beginning, middle and the end of the weld. The specimen extracted at the beginning of the weld showed low tensile properties compared to specimens extracted from different locations of the weld. There was no certain trend noted through the bending results. All three specimens showed dimpled fracture which is the characterization of the ductile fracture.

The aim of this work was to investigate the microstructure and the mechanical properties of la-ser-welded joints combined of DP800 and DP1000 high strength thin steel sheets. The welded joints (WJ) comprised of similar/dissimilar steels with similar/dissimilar thickness were consisted of different zones and exhibited similar microstructural characteristics. The trend of microhard-ness for all WJs was consistent, characterized of the highest value at hardening zone (HZ) and lowest at softening zone (SZ). The degree of softening was more severe and the size of SZ was wider in the WJ combinations of DP1000 than DP800. The tensile test fractures were located at the base material (BM) for all DP800 weldments, while the fractures occurred at the fusion zone (FZ) for the weldments with DP1000 and those with dissimilar sheet thicknesses. The DP800-DP1000 weldment presented similar yield strength (YS) and ultimate tensile strength (UTS) values but lower elongation (EI) in comparison with the DP800-DP800 weldment, which showed similar strength properties as the BM of DP800. However, the EI of DP1000-DP1000 weldment was much lower in comparison with the BM of DP1000. The DP800-DP1000 weldment with dissimilar thicknesses showed the highest YS and UTS values compared with the other weldments, but with the lowest EI. The fatigue fractures occurred at the WJ for all types of weldments. The DP800-DP800 weldment had the highest fatigue limit and DP800-DP1000 with dissimilar thick-nesses had the lowest fatigue limit. The fatigue crack initiated from the weld surface.

This study aimed to investigate the fatigue performance and interfacial strengthening mechanisms of Al6061-to-Cu dissimilar lap joints via electromagnetic pulse welding (EMPW). The load-bearing capacity of the joints at discharge voltages of 14 kV and 16 kV was superior to that of 12 kV. Furthermore, the fatigue life of the 14 kV joints was one order of magnitude higher compared to the 12 kV joints. SEM observation of the fatigue fracture surface revealed the presence of typical "tire-mark" fatigue striations only in the 14 kV joint, indicating higher ductility and the ability to withstand extended plastic deformation. Notably, ultra-fine nanocrystalline Al2Cu phase, amorphous phase, and numerous dislocations hindered EBSD acquisition in the transition zone. Nevertheless, dense low-angle grain boundaries (LAGBs) and refined grains were examined at the bonding interface. This suggests that the high-velocity collision caused severe plastic deformation and led to the formation of substructures. The interfacial strength was attributed not only to the "wave-like" or "inverted hook-like" diffusion layer but also to the presence of refined grains along the interface and nanocrystalline Al2Cu in the transition zone. Furthermore, the hybrid nanocrystalline-amorphous microstructure strengthened the joint by regulating the balance between strength and ductility.

This study investigated the fatigue properties and interfacial strengthening mechanisms of Al6061-to-Cu dissimilar welded joints via electromagnetic pulse welding (EMPW). The load-bearing capacity of the joints at discharge voltages of 14 kV and 16 kV was superior to that of 12 kV. Meanwhile, the fatigue life of 14 kV joints was one order of magnitude higher than that of 12 kV. The SEM observation on the fatigue fracture surface shows that the typical “tire-mark” fatigue striation just appeared on the 14 kV joint, indicating higher ductility for handling more extended plastic deformation. The high EBSD acquisition was achieved except for the transition zone due to the formation of ultra-fine nanocrystalline Al2Cu phase and amorphous phase, along with many dislocations. Dense low-angle grain boundaries (LAGBs) and refined grains are formed along the bonding interface. This indicates that severe plastic deformation induced dislocations to form the substructure in such an instant (40-60 μs) during the high-velocity collision. The interfacial strength is not only due to the continuous interfacial diffusion layer with a “wave-like” or “inverted hook-like” pattern but also benefits from refined grains along the interface and in the transition zone, as well as the hybrid amorphous-nanocrystalline microstructure, which strengthens the joint through increasing ductility induced by refined grains and regulating amorphous or nanocrystalline phases to affect the balance between strength and ductility of the Al/Cu joint.

There is an increase towards reducing the weight of structures through the use of aluminium alloys in different industries like aerospace, automotive, etc. This growing interest would lead towards using dissimilar aluminium alloys which would require welding. TIG and friction stir welding are the well-known techniques that are currently suitable for joining dissimilar aluminium alloys. The welding of dissimilar alloys has its own dynamics which impact on the quality of the weld. This then suggests that there should be a process which can be used to improve the dissimilar alloys welds post their production. Friction stir processing is viewed as one of the techniques that could be used to improve the mechanical properties of the material. This paper reports on the status and the advancement of FSW, TIG and FSP technique. It further looks at the variation use of FSP on TIG and FSW welded joints with the purpose of identifying the knowledge gap.

Dissimilar welds between ferritic and austenitic steels represent a good solution for exploiting the best performance of stainless steels at high and low temperatures and in aggressive environments, while minimizing costs. Therefore, they are widely used in nuclear and petrochemical plants, however, due to the different properties of the steels involved, the welding process can be challenging. Fusion welding can be specifically addressed to connect low-carbon, or low-alloy steels, with high-alloy steels, which have similar melting point. Welding of thick plates can be performed with electric arc in multiple passes or in a single pass by means of a laser beam equipment. Since microstructure and consequently mechanical properties of the weld are closely related to composition, the choice of the filler metal and processing parameters, which in turn affects the dilution rate, plays a fundamental role. Numerous technical solutions were proposed for welding dissimilar steels and much research was developed on the weldment metallurgy; therefore, this article is aimed at a review of the most recent scientific literature on the issues relating to the fusion welding of ferritic / austenitic steels. Two specific sections are dedicated respectively to electric arc and laser beam welding; finally, metallurgical issues, related to dilution and thermal field are debated in the discussion section.

The strength of laser joined metal and plastic hybrids is based purely on adhesion. Unpolar plastics like polypropylene depend solely on the mechanical adhesion while polar plastics like polyamide 6.6 develop covalent bonds with the metal. In this research the influence of different surface metallizations on the lap shear strength of laser joined hybrids was investigated. Sandblasted AISI 304 was used as base metal and reference. Aluminum and titanium coatings were deposited by the means of Arc-PVD. Polypropylene and polyamide 6.6 were utilized as polar und unpolar plastics. The lap shear strength of all hybrids with polyamide 6.6 was higher than the polypropylene samples. For all investigated variations of the laser power, scanning speed and the cohesive and adhesive failure modes, the samples joined with the sandblasted AISI 304 showed the highest lap shear strength. The reduction in lap shear strength for the coated samples was due to the increased difference in thermal conductivity between the plastics and the coating materials. This lead to increased warping and residual stresses. It can be concluded that the thermal properties of the metallization in laser joined metal and plastic hybrids has a high impact on the lap shear strength.

This paper investigates if the polar groups induced by a plasma treatment can increase the lap shear strength of laser joined metal and plastic hybrids. Optimal laser joining parameters for cold-rolled AISI304 – Polyamide 6.6 and sandblasted AISI304 - Polypropylene hybrids are developed. The OWRK-method was utilized to identify the change in surface free energy of a low-pressure plasma treatment. Plasma treated samples were joined and tested. The fractured surfaces were investigated via light microscopy and SEM. The arithmetic means of the plasma treated hybrids lap shear strength with polyamide 6.6 varied slightly but all measured values were within the range of the untreated samples. The lap shear strengths of the polypropylene hybrids were significantly reduced. This was attributed to an overaging and the development of low molecular weight oxidized materials which lead to a weak boundary layer. No correlation between surface free energy and the lap shear strength could be found.