The role of force and torque in friction stir welding: A detailed review

Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding. The application of FSW relies on the development of cost-effective, durable tools that consistently produce high-quality welds. The forces an...

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Published inJournal of advanced joining processes Vol. 11; p. 100289
Main Authors Akbari, Mostafa, Esfandiar, Milad, Abdollahzadeh, Amin
Format Journal Article
LanguageEnglish
Published Elsevier B.V 01.06.2025
Elsevier
Subjects
FEM
Force
FSW
Measurement
Torque
Measurement
Torque
FSW
Force
FEM
Online AccessGet full text
ISSN2666-3309
2666-3309
DOI10.1016/j.jajp.2025.100289

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Abstract Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding. The application of FSW relies on the development of cost-effective, durable tools that consistently produce high-quality welds. The forces and torque generated during welding are critical to this process, which influence weld integrity, process efficiency, and tool longevity. This review explores methodologies for estimating these parameters—analytical, numerical, and experimental—and discusses measurement techniques, including direct and indirect methods. It also examines variations in forces across different FSW types, such as Conventional FSW, Bobbin Tool FSW, and Stationary Shoulder FSW, emphasizing the differences in their operational mechanics. Additionally, the review highlights how process parameters like tool shape, size, tilt angle, and welding speed can be optimized to enhance performance and investigates the use of force measurements for real-time weld monitoring and defect detection, contributing to the reliability of FSW in industrial applications. The results indicate that the use of force measurement for online monitoring of welding processes, particularly concerning welding defects and overall weld quality, has garnered significant attention in recent years. ​ A notable advancement in this field is the implementation of machine learning tools, which enhance the ability to predict potential weld defects and improve overall weld quality. This innovative approach not only streamlines the monitoring process but also contributes to the evolution of FSW technologies, ensuring higher standards of quality and safety in various applications.
AbstractList Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding. The application of FSW relies on the development of cost-effective, durable tools that consistently produce high-quality welds. The forces and torque generated during welding are critical to this process, which influence weld integrity, process efficiency, and tool longevity. This review explores methodologies for estimating these parameters—analytical, numerical, and experimental—and discusses measurement techniques, including direct and indirect methods. It also examines variations in forces across different FSW types, such as Conventional FSW, Bobbin Tool FSW, and Stationary Shoulder FSW, emphasizing the differences in their operational mechanics. Additionally, the review highlights how process parameters like tool shape, size, tilt angle, and welding speed can be optimized to enhance performance and investigates the use of force measurements for real-time weld monitoring and defect detection, contributing to the reliability of FSW in industrial applications. The results indicate that the use of force measurement for online monitoring of welding processes, particularly concerning welding defects and overall weld quality, has garnered significant attention in recent years. ​ A notable advancement in this field is the implementation of machine learning tools, which enhance the ability to predict potential weld defects and improve overall weld quality. This innovative approach not only streamlines the monitoring process but also contributes to the evolution of FSW technologies, ensuring higher standards of quality and safety in various applications.
ArticleNumber 100289
Author Akbari, Mostafa
Abdollahzadeh, Amin
Esfandiar, Milad
Author_xml – sequence: 1
  givenname: Mostafa
  orcidid: 0000-0002-6952-8570
  surname: Akbari
  fullname: Akbari, Mostafa
  email: Mo-Akbari@nus.ac.ir
  organization: Department of Mechanical Engineering, National University of Skills (NUS), Tehran, Iran
– sequence: 2
  givenname: Milad
  surname: Esfandiar
  fullname: Esfandiar, Milad
  organization: Department of Mechanical Engineering, National University of Skills (NUS), Tehran, Iran
– sequence: 3
  givenname: Amin
  surname: Abdollahzadeh
  fullname: Abdollahzadeh, Amin
  organization: School of Metallurgy & Materials Engineering, Iran University of Science and Technology (IUST), Tehran, Iran
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Torque
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Force
FEM
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Snippet Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding....
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SubjectTerms FEM
Force
FSW
Measurement
Torque
Title The role of force and torque in friction stir welding: A detailed review
URI https://dx.doi.org/10.1016/j.jajp.2025.100289
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