Friction stir welding (FSW) is a new, efficient way of solid state welding technology used to join ferrous and non-ferrous materials such as aluminium alloys and steels with ease. FSW technique produces reliable similar and dissimilar joints. In FSW the major process parameters namely the tool rotational speed, tool transverse speed, axial force and tool geometry which are affecting the microstructure characteristics of weld zone and the mechanical properties of the joint. The purpose of this assess is to provide a widespread overview of friction stir welding (FSW), in addition to introduce current research and applications concerning this relatively new process. As well as highlights of current research in this area and applications of this process in various industries will also be presented and discussed.

FSW is capable of welding both similar and dissimilar metal and is having a enormous growth potential due to its inherent benefits. This review gives a clear idea about the trend of research going on in this new field, the effect of process parameters on weld joint and applications of FSW in industrial sector. Some essential conclusions listed from this review are: FSW controls the formation of intermetallic compounds and produces a fine recrystallized grain structure in the weld zone. Process parameters greatly influence the microstructure and mechanical properties of the weld joint. FSW has many applications in various industries like aerospace, defense, nuclear and transportation. The further research can be carried out on FSW to predict process parameters using new techniques such as neural networks, response surface methodology.

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