Quality and Performance A Critical review on Optimization of Process Parameters in Friction Stir Welding: Enhancing Weld

Abstract

Its ability to join materials without melting, offering superior mechanical properties and reduced defects compared to conventional welding methods. This paper examines the critical process parameters influencing FSW, including tool design, rotational speed, traverse speed, axial force, and tilt angle, among others. The interplay of these parameters dictates joint quality, microstructural evolution, and mechanical performance. Understanding and optimizing these factors is crucial for enhancing weld Friction stir welding (FSW) is a solid-state welding process that has gained significant attention for integrity and broadening the application of FSW across various industries. This study provides an in-depth analysis of each parameter, highlighting their roles and effects on weld outcomes through empirical research and case studies.

Cite as:

S. Gopalakrishnan, & V. Anbumalar. (2025). A Critical review on Optimization of Process Parameters in Friction Stir Welding: Enhancing Weld. Research and Reviews on Experimental and Applied Mechanics, 8(2), 1–8. 

https://doi.org/10.5281/zenodo.16261331