Study on Joining Challenges in Friction Stir Welding of Composite Materials

Abstract

In this chapter, the joining challenges of friction stir welding (FSW) are covered, with a focus on the integration of hybrid composite materials such as MMCs (metal matrix composites) and PMCs (polymer matrix composites). It describes the difficulties in welding various composites due to the usage of different material characteristics with exact control over the welding parameters and tool design, and FSW factors on the quality of the weld. It also covers how material choice and tool shape affect fault mitigation. It illustrates current developments in FSW tool design and materials, highlighting creativity to meet obstacles. Effective techniques for producing FSW joints with a long lifespan are demonstrated by best practices in the automobile industry. In order to optimize FSW procedures for hybrid composite structures, the chapter intends to serve as a reference for engineers and researchers.