Dissimilar Metal Bonding by Friction Stir Welding: Magnesium to Steel Joints

Abstract

FSW - Friction stir welding has extended recognition as an effective non-fusion welding process for dissimilar materials, offering a solution to the limitations commonly encountered in conventional fusion welding techniques. This review paper focuses on the FSW of magnesium to steel, which has gained significant attention in different industries, like energy sector, aerospace, marine, automotive, etc. The paper presents an overview of the magnesium and steel materials, discusses the challenges and considerations specific to their dissimilar FSW, and provides insights into the mechanical characteristics, microstructural development, process parameters, and joint performance of the magnesium to steel welded joints. This paper highlights the current state of research, identifies knowledge gaps, and suggests future research directions. This information will be valuable for researchers, engineers, and practitioners involved in the development and application of dissimilar material joining techniques in various industries. The present review paper outlines FSW parameters including tool design, rotating speed, feed, tilt angle, pin offset, and the positioning of workpiece in a clamp for dissimilar FSW systems.