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Journal of Magnesium and Alloys 6 (2018) 399–416

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Review
Review on friction stir welding of magnesium alloys
Kulwant Singh a,∗, Gurbhinder Singh b, Harmeet Singh a
a I. K. Gujral Punjab Technical University, Kapurthala, Punjab, India
b Guru Kashi University, Talwandi Sabo, Punjab, India

Received 16 May 2018; received in revised form 27 June 2018; accepted 28 June 2018
Available online 18 July 2018

Abstract
Friction Stir Welding (FSW) is considered to be the most significant development in metal joining in last two decades. FSW has many
advantages when welding magnesium or lightweight alloys. The Friction stir welding of magnesium alloy has many potential applications
in major industries i.e. land transportation, aerospace, railway, shipbuilding and marine, construction, and many other industrial applications.
Even magnesium alloys have been used in industrial equipment of nuclear energy as magnesium alloys have low tendency to absorb neutrons,
sufficient resistance to carbon dioxide and excellent thermal conductivity. Recently, the research and development in FSW field and associated
technologies have been developing rapidly worldwide. In this review article, the basic principle of friction stir welding and several aspects
of friction stir welded magnesium alloys have been described. The current state of friction stir welding of magnesium alloys is summarized.
In spite of this, much remains to be learned about the process and opportunities for further research are identified.
© 2018 Published by Elsevier B.V. on behalf of Chongqing University.
This is an open access article under the CC BY-NC-ND license. (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review under responsibility of Chongqing University

Keywords: FSW; Tool Geometry; Stir Zone; Mg Alloy; Texture; Microhardness.

1. Introduction are ternary in nature and made up of aluminium, zinc, tho-

On the Earth’s surface, Magnesium is the 6th most abun-
dant element and characterizes approximately 2.5% of its
composition [1]. Magnesium is also the 3rd most plentiful el-
ement dissolved in seawater, about a concentration of 0.14%
[2]. Due to the lightweight properties, magnesium alloys (Mg
alloys) have outstanding specific strength [3], sound damping
capabilities [4], hot formability [5], good castability [6], and
recyclability [7]. Due to the hexagonal close-packed (HCP)
crystal structure, magnesium alloys possess limited strength,
fatigue and creep resistance at elevated temperatures [8] and
low stiffness [3], limited ductility [9] and cold workability
at room temperature [10]. Magnesium alloys exhibit poor
hardness, wear and corrosion resistance properties [11], large
shrinkage during solidification [8], and high chemical reactiv-
ity (molten state) [12]. Most commercial magnesium alloys
∗ Corresponding author.
E-mail address: kskookna@gmail.com (K. Singh).
https://doi.org/10.1016/j.jma.2018.06.001
2213-9567/© 2018 Published by Elsevier B.V. on behalf of Chongqing University. This is an open access article under the CC BY-NC-ND license.
(http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer review under responsibility of Chongqing University
rium and rare earth. In this ternary Mg-Al series, aluminium
is the main alloying element that involves AZ (Mg-Al-Zn),
AM (Mg-Al-Mn) and AS (Mg-Al-Si) alloys [13,14]. It is the
part of common practice to classify Mg alloys on the ba-
sis of room and elevated temperature applications. For high-
temperature application alloys, the chief alloying elements are
rare earth metals and thorium whereas aluminium and zinc are
used as alloying elements for room temperature applications
[1]. For designation of these magnesium alloys, currently, use
the American Society for Testing Materials (ASTM) standard.
In sequence, the first two letters indicate the principal code for
major alloying elements as Table 1 shows. These two letters
are followed by two numbers, indicating the concentration of
the major alloying elements. The fifth symbol is a letter, sig-
nifying the alloy modification. In some cases, this alloy code
is followed by a designation of temper that is similar to the
Temper designation of aluminum alloys: F –As fabricated,
O – Annealed, H – Cold worked, T4 – Solution treatment
and natural aged, T5 – Artificial aging, and T6 – Solution
treatment followed by artificial aging [15,16].
400 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
Table 1
Alloying element code for magnesium alloys [1,15].
Code Element Code Element
A Aluminum N Nickel
B Bismuth P Lead
C Copper Q Silver
D Cadmium R Chromium
E Rare earths S Silicon
F Iron T Tin
H Thorium W Yttrium
K Zirconium Y Antimony
L Lithium Z Zinc
M Manganese
Fig. 1. Representation of friction stir welding process [34].
The strength to weight ratio is making magnesium alloys
important material for applications where weight reduction
is important, and where it is imperative to reduce inertial
forces. Because of this property, denser material, not only
steels, cast iron and copper base alloys, but even aluminium
alloys are replaced by magnesium-based alloys in a variety of
automotive and structural applications by magnesium alloys
[16,17]. Thus, magnesium alloys have considerable applica-
tions in aerospace, automotive, aircraft, electronics and other
industries [18–21]. Even these alloys have been used in in-
dustrial equipment of nuclear energy as Mg alloys have low
tendency to absorb neutrons, sufficient resistance to carbon
dioxide and excellent thermal conductivity [22]. Generally,
these alloys have not been welded because of the occurrence
of defects such as cracks, oxide layers, and cavities [23].
However, the broader utilization/application of magnesium al-
loys requires reliable joining/welding processes [3]. Magne-
sium alloy may be joined using mechanical fasteners as well
as a variety of welding techniques including tungsten-arc inert
gas [24,25], metal-arc inert gas [26], plasma arc [27], laser
[28], ultrasonic [29], and friction stir welding [30,31]. Fric-
tion stir welding (FSW), a solid-state joining technique was
invented and developed by The Welding Institute (TWI) of
United Kingdom [32,33]. The Schematic drawing of FSW is
shown in Fig. 1.
In Friction stir welding, a non-consumable rotating tool
with a pin and shoulder is inserted into the abutting edges
of plates to fabricate the joint and traversed along the line of
the joint [35]. The side of the weld where the direction of
welding is in agreement with the rotational direction of the
tool is known as the advancing side and the other side, where
the direction of welding opposite the rotational direction of
the tool is known as the retreating side [36]. An important
feature of the welding tool is a probe/pin which protrudes
from the base of the tool i.e. the shoulder and a length only
marginally less than the thickness of the plate/workpiece. In
this process, the heating is accomplished by friction between
the rotating tool and the workpiece and plastic deformation
of workpiece material [37]. This localized heating softens the
workpiece material around the pin before it reaches its melt-
ing point [38]. The combination of welding tool rotation and
translation leads to the movement of soft material from the
front of the tool pin to the back of the tool pin [39]. As
the result of this process, a joint is produced in solid state
[40,41].
FSW has many advantages over the other welding tech-
nique when welding magnesium alloys or lightweight alloys
[12]. The advantages of friction stir welding process are illus-
trated in Table 2. The research and development in FSW field
and associated technologies have been developing rapidly,
with many companies, research institutes and universities. To-
day there are about 300 companies worldwide using FSW
and 1900 patent applications had been filed relating to FSW
[42–44]. The number of research publications has also grown
exponentially. In this paper, the current state of understanding
and development of friction stir welded magnesium alloys are
reviewed.
2. Friction stir welding factors
The FSW process involves a complex phenomenon re-
lated to plastic deformation and material movement during the
welding process. The major factors affecting FSW process are
(1) Tool Geometry, (2) Welding parameters, (3) Joint config-
uration. These factors play an important role in the material
flow pattern and temperature distribution [46–49].
2.1. Tool geometry
Tool geometry has the significant influence in FSW pro-
cess. Earlier researchers report that the tool geometry plays a
critical role in material flow and governs the traverse rate of
FSW process [50]. Padmanabham et al. [51] studied the effect
of tool pin profile, shoulder diameter and tool material on the
friction stir welding of AZ31B Mg alloy. Fig. 2 shows the tool
consists of a shoulder and a pin used for investigation. It was
concluded that the joints fabricated by high carbon steel tool
with 66 HRC with threaded pin profile and a shoulder diame-
ter of 18 mm (keeping D/d ratio = 3) showed excellent tensile
properties. Due to the higher coefficient of friction, the tool
material which has higher hardness may generate more heat.
Fig. 3 represents the shoulder shapes and surface features,
FSW tool probes, and friction stir welding tools designed at
TWI.
Weglowski
˛ and Pietras [53] reported that during the weld-
ing process, FSW tool has two principal functions- (i) lo-
 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416 401

Table 2
Advantages/Benefits of friction stir welding over others joining processes [32,45].

Sr. No. Area Benefits

1 Metallurgical
2 Environmental
3 Energy
4 Safety
5 Mechanical Characteristics
a. Fine microstructure
b. Absence of cracking
c. Solid phase method
d. No loss of alloying elements during process
e. Low distortion and shrinkage, even in long welds
f. Good dimensional stability and repeatability
g. Excellent metallurgical properties of the weld joint
h. Substitute for multiple parts joined by fasteners
a. Eliminate grinding wastes
b. Shielding gas not required
c. No surface cleaning requisite
d. Elimination of solvents for degreasing
e. No Consumable materials required, such as rugs, wire or any other gases
a. Improved materials use allows reduction in weight (e.g., joining different thickness)
b. Very Less energy needed (about 2.5% of the energy desirable for a laser weld)
c. Decreased fuel consumption due to light weight aircraft, automotive, structure and ship applications
a. No welding arc or fumes
b. No UV-radiations
c. No spatter
a. High weld strength and toughness.
b. Weld resists fatigue stress.
c. Minimal distortion of the joined parts.

the FSW process loads and also homogeneity in microstruc-

Fig. 2. Nomenclature of FSW tool [52].
calized heating, and (ii) material flow. Colligan and Mishra
[55] and Dobriyal et al. [56] described that the heat is pro-
duced in the initial stage of tool plunge due to the friction
between pin and workpiece and some additional heating re-
sulted from deformation of the material. The tool pin is be-
ing plunged into workpiece till the tool shoulder touches the
workpiece surface [57]. The shoulder is marginally inserted
under the workpiece surface. Mishra and Ma [32], Elango-
van et al. [58] and Deya et al. [59] reported that the fric-
tion between the tool shoulder and workpiece resulted in the
major component of heating. From this heating feature, the
size of pin and shoulder is very important than the other de-
sign features of the tool. Xu et al. [60] and Rajakumar et al.
[61] stated that the shoulder of the tool provides confinement
for the heated volume of workpiece material. It is reported
that the second function of the FSW tool is to stir/blend and
move the material during the process. The tool design governs
ture and properties of joint. Zhao et al. [62] studied the im-
pact of the tool designed with different shoulder diameters
during the friction stir welding of AZ31 Mg alloy. They ana-
lyzed the effect of these parameters on the formability of the
material and its mechanical properties. They produced joints
containing fine refined grains in the joint zone. Patel et al.
[63] studied the influence of tool pin profile and welding
parameter on the tensile strength of magnesium alloy AZ91
during FSW process. They concluded that heat generation is
important for proper welding which is produced by friction
between shoulder and plates. The shoulder diameter of 18 mm
with threaded straight cylindrical pin profile, at the rotational
speed of 710 rpm and the welding speed of 28 mm/min was
found to be suitable to produce sound weld having high ten-
sile strength. Tozaki et al. [64] and Bakavos and Prangne
[65] reported that good weld joints can be obtained using a
probe free shoulder tool with the bottom scrolled shoulder sur-
face. This feature played a significant role in stirring/blending
the material. Here, the tool shoulder outer surface shape and
feature becomes more important. Generally, a concave shoul-
der and threaded cylindrical pins are used [66–68]. The cost-
effective and long life tools are still challenges for researchers
for the FSW of soft alloys [69,70]. The Tool material proper-
ties (strength, hardness, fracture toughness, thermal expansion
coefficient and thermal conductivity) affect the weld qual-
ity, tool wear and performance of tool [71–73]. The hard-
ness of materials used for FSW tools such as stainless steel,
high-speed steel, armour steel, mild steel and high carbon
steel is 40, 73, 58, 30 and 66 HRC respectively [74]. Table
3 lists the tool materials, tool geometries and welding operat-
ing parameters used to weld various grades of the magnesium
alloys.
402 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416

Fig. 3. (a) Shoulder shapes and surface features, (b) FSW tool probes, and (c) Friction stir welding tools designed at TWI [54].

2.2. Welding parameters
In friction stir welding process, there are two important
parameters: (i) tool rotation rate (rpm) in clockwise or coun-
terclockwise direction and (ii) tool traverse speed (mm/min)
along the line of joint [75]. The rotation of tool results in stir-
ring and mixing of material around the rotating pin and the
translation of tool moves the stirred material from the front to
the back of the pin and finishes welding process [76]. Lee W.
et al. [77] studied the effect of different friction stir welding
Table 3
Summary of tool materials, geometries and welding variables used for FSW of several magnesium alloys.

Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference
AZ31 Magnesium Tool steel Concave Shoulder diameter - 15 mm Pin Tool Rotational Speed- 2000 rpm Crack propagation [96]
alloy length - 3.7 mm (M5 threaded) Tool Welding Speed-200 mm/min was influenced by the
tilting angle - 3° “onion-ring structure”
of the stir zone
AZ31 Magnesium H13 tool steel Conical pin Shoulder diameter −18 mm Pin Tool Rotational Speed-800 to Superior [103]
alloy height −7.8 mm Pin diameter - 9 & 1600 rpm Welding comprehensive
6 mm, Tool tilt angle −2.5° Speed-120 mm/min mechanical
performance of the
FSW joints has been
achieved at a

K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416

moderate tool
rotation rate of 1200
rpm
AZ31–O Magnesium – Concave Shoulder diameters - 10 & 13-mm Tool Rotational Speed- 600 to Weld quality was [97]
Alloy Threaded pin diameter - 4 & 5 mm 1300 rpm Welding speed- 200 to improved with
2000 mm/min Axial force- 6.5 to increase in load
9 kN and 22 kN during applied, weld speed
2000 mm/min and rotation rate
AZ31B M35 grade HSS (60– Taper cylindrical pin profiled Shoulder Length −10 mm Shoulder Tool Rotational Speed- 45 to Optimized process [40]
62 HRC) Diameter-12 mm Pin 1500 rpm Welding Speed-0.25 to parameter at constant
Length-4.75 mm Pin Diameter-4 mm 500 mm/min Axial Force-3kN axial force
D / d ratio of the tool-3
AZ31B High speed steel Taper with Threaded pin Pin length-4.8 mm Shoulder Tool Rotational Speed- 900 to Obtained higher [74]
(HSS), Stainless steel diameter - 18 mm Axial force- 5 kN 1800 rpm Welding mechanical properties
(SS) Tilt angle - 2.5° Pin diameter- Speed-40 mm/min with SS tool at a
6 mm D/d Ratio of tool-3 rotational speed of
1120 rpm
AZ31B Stainless steel, High Taper with Threaded pin Pin length-6 mm Shoulder diameter Tool Rotational Speed- 900 to Rotational speed and [47]
speed steel, H13 tool - 18 mm Tilt angle - 2° D/d Ratio 1400 rpm Welding traverse speed tool
steel of tool 3 Speed-25–75 mm/min material influenced
the mechanical
properties of
material.
AZ31B HSS Taper Cylindrical pin Shoulder diameter - 12 mm Pin Tool Rotational Speed-1800 rpm High tensile strength [92]
diameter - 4 mm Pin length - Welding Speed-50 mm/min Axial obtained with an
4.85 mm Force- 3 to 5 kN axial force of 5kN
AZ31B Magnesium Mild Steel, Stainless Straight cylindrical, Tapered Shoulder diameters 15 mm, 18 mm Tool Rotational Speed-1600 rpm The joints fabricated [52]
alloy Steel, Armour Steel, cylindrical, Threaded Cylindrical, & 21 mm Pin diameter- 6 mm D/d Welding speed- 0.67 mm/s Axial by high carbon steel
High Carbon Steel, Triangular, Square ratio of tool - 2.5, 3.0 & 3.5 Pin force- 3 kN tool with threaded
High Speed Steel length - 5.7 mm Tool tilt angle 0° pin profile and
shoulder diameter of
18 mm (D/d = 3.0)
exhibited superior
tensile properties
(continued on next page)

403
 404
Table 3 (continued)

Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference

AZ31B Magnesium Tool Shoulder made Screw tip geometry Shoulder diameter - 25 mm Probe Tool Rotational Speed-1500 to Tensile strength value [108]
alloy of AISI 1040 steel, diameter - 5 mm Pin length - 4 mm 2300 rpm Welding speed - 100 to of joints observed
Tool screw tip made 190 mm/min lower than the tensile
of HSS steel. strength value of the
base material.
AZ31B-H24 Mg H13 steel tool Scrolled left-hand threaded pin Shoulder diameter - 19.05 mm Pin Welding Speed-10 mm/s or 20 mm/s. The hardness [93]
alloy (Lap Joint) (46.6–50 HRC) diameter - 6.35 mm Pin length - Tool Rotational Speed- 1000 rpm decreased from the
2.75 mm Tilt angle - 0.5° and 1500 rpm base metal to the stir
zone across the
heat-affected zone

K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416

and
thermo-mechanically
affected Zone.
AZ31B-H24 H13 steel Scrolled left-hand threaded pin Shoulder diameter - 19.05 mm Pin Tool Rotational Speed-2000 rpm The highest shear [98]
Magnesium alloy diameter - 6.35 mm Pin length - Welding speed- 5 to 30 mm/s strength obtained
(Lap Joint) 2.75 mm using a set of
welding parameters
resulting in
downward hooking
defect at the
maximum stress
location of the top
sheet
AZ31B-H24 H13 steel Scrolled left-hand threaded pin Shoulder diameter - 19.05 mm Pin Tool Rotational Speed-500 to Tensile shear load [99]
Magnesium alloy diameter - 6.35 mm Pin length - 2000 rpm Welding speed- 20 mm/s initially increases
2.75 mm with increasing tool
rotational speed but
decreases with
further increase.
Shear strength
increases with
increasing probe
length and
penetration depth into
the bottom sheet
AZ31B-H24 H13 Steel Scrolled with right hand threaded Shoulder diameter - 9.50 mm Pin Tool Rotational Speed- 2000 rpm The yield strength [106]
Magnesium alloy pin diameter- 3.175 mm Pin length - Welding speed - 5 to 30 mm/s increases with
1.7 mm Ttilting angle 0.5° increasing welding
speed. The tensile
strength increases
with increasing
welding speed up to
15 mm/s but remains
constant from 15 to
30 mm/s
(continued on next page)
Table 3 (continued)

Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference

AZ31B-O Mg alloy High Carbon High Cylindrical pin with Left hand Shoulder diameters - 18 mm and Tool Rotational Speed-1200 & Tensile strength [95]
Chromium Steel thread 1 mm (pitch) 20 mm Pin diameter- 7 mm Pin 1950 rpm Welding speed −40 & increases with
length - 4.8 mm D/d ratio of tool - 60 mm/min increase in the value
2.56 and 3 of weld pitch. high
tensile strength of
187.8 N/mm2 (91%
of base material) was
achieved at high weld
pitch of 0.050 mm/rev
with tool shoulder
diameter of 20 mm
AZ61 Mg alloy SKD61 steel (48–50 Concave (M4 thread) Shoulder diameter - 12 mm Pin Tool Rotational Speed-1250 & Strength of an FSSW [100]

K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416

(FSSW) HRC) length - 4 mm Plunge depth of tool
penetration - 4.2 mm
AZ61 Mg alloy H13 steel Threaded cylindrical pin Shoulder diameter - 18 mm Tool pin
diameter - 6 mm D/d ratio of tool -
3.0 Pin length – 3.8 mm Tool
inclined angle - 0°
AZ61A Mg alloy High Carbon Steel Threaded cylindrical pin Shoulder diameter - 18 mm Tool pin
diameter - 6 mm D/d ratio of tool -
3.0 Pin length - 5.9 mm Tool
inclined angle - 0°
AZ31 and AZ91 H13 tool steel Taper pin with Threads Shoulder diameter - 15 mm Pin
length - 6 mm
2500 rpm Plunge rate- 1 to 2 mm/s
Dwell Time – 0 to 8 sec
Tool Rotational Speed-1400 rpm
Welding speed- 25 mm/min
Tool Rotational Speed-1200 rpm
Welding speed- 90 mm/min Axial
force- 3 to 7 kN
Tool Rotational Speed-1400 to
1800 rpm Welding
Speed-25–100 mm/min
can be improved by
increasing dwell time
The elongated grains [155]
of the base metal
were recrystallized in
the stir zone and in
transition zone during
friction stir welding.
The formation of
finer grains in the stir
zone of the joint is
responsible for
increase the hardness
of the stir zone. The
microhardness of
base metal is higher
than that of
thermo-mechanically
affected zone but
lower than that of
stir zone.
The joints fabricated [101]
under an axial force
of 5 kN, rotational
speed of 1200 rpm
and welding speed of
90 mm/min exhibit a
maximum tensile
strength of 224 MPa
(83% of the base
metal) compared to
other joints.
Optimized process [94]
parameters to
eliminate the hot
cracking

405
(continued on next page)
 406
Table 3 (continued)

Work piece material Tool material Tool shape Tool size Operating parameters Remarks Reference

AZ 91 Magnesium HCHCr D2 grade (60 Threaded straight cylindrical pin, Shoulder diameters - 18 mm Pin Tool Rotational Speed-710 to High tensile strength [63]
Alloy to61 HRC) Tapper cylindrical pin, Straight diameter- 6 mm Pin length - 5.8 mm 1400 rpm Welding Speed - 28 to obtained with
cylindrical pin 56 mm/min threaded straight

K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416

cylindrical pin profile
tool at 710 rpm of
tool rotational speed
and 28 mm/min
welding speed
AZ91 Magnesium H13 steel Conical, Conical threaded, Shoulder diameter- 18 mm Probe Tool Rotational Speed- 900 to Tensile properties [107]
alloy Cylindrical, Cylindrical threaded diameter- 6 mm Pin length- 5.5 mm 1400 rpm Welding speed 25 to increased with
40 mm/min increase in rotational
speed of tool.
AZ91 Mg Alloy 2344 Hot Working Cylindrical pin Pin diameter – 5 mm Pin length - Tool Rotational Speed-710 to There is good [102]
Steel 4.8 mm Shoulder diameter - 18 mm 1400 rpm Welding Speed-25 to agreement between
Tool tilt angle - 3° 100 mm/min results of numerical
models and
experiments in the
aspects of welding
forces, temperature
history and grain
size.
AZ91C Magnesium AISI H13 hot Square pin profile Shoulder diameter- 18 mm Square Tool Rotational Speed-800 to Water, as a welding [105]
alloy working steel Pin- 4.25 × 4.25 mm2 Pin length- 1600 rpm Welding Speed- 40 mm/ environment, has a
2.6 mm Tool tilt angle - 3° min considerable impact
on the mechanical
properties of the
weld.
AZ91D Mg alloy H13 tool steel Tapered cylindrical pin left hand Shoulder diameter-18 mm Pin Tool Rotational Speed-1025 to Tensile strength and [104]
threaded diameter- 7 mm (shoulder end) and 1525 rpm Welding speed- 25 to hardness were
2 mm (tip end) Pin length- 2.6 mm 75 mm/min improved due to the
grain refinement in
the stir zone
 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
Fig. 4. Joint configuration (a) Square butt joint [92] (b) Overlapped joint [93].
parameters on the mechanical properties of AZ31B-H24 mag-
nesium alloy joints and reported that joint strength increased
with increasing tool rotation speed and decreasing welding
speed, whereas Lim et al. [78] found no significant effect
of processing parameters on the tensile strength of friction
stir welded AZ31B-H24 alloy. In addition to the tool rotation
speed and traverse speed, some another process parameters
are the angle of spindle or tool tilt with respect to the work-
piece surface, target depth and axial force [79–81]. A suit-
able tool tilt towards trailing direction ensures that the tool
shoulder holds the stirred material and move material effi-
ciently from the front side of the pin to the back of the pin
[82]. The insertion/target depth of the tool pin into the work-
pieces is also an important factor for producing sound welds.
The target depth of pin is related to the tool pin height. The
tool shoulder face always kept in contact with the surface
of workpiece to move the stirred material effectively to pro-
duce solid state joint. This can be done by proper selection
of the insertion/target depth of the tool pin. Bahari [83] re-
ported that the insertion depth should not be too shallow or
too deep. In the case when it is of very little depth, the tool
shoulder does not contact the original workpiece surface and
cannot move the stirred material efficiently which resulted in
the generation of welds with inner channel/surface groove.
And when the insertion depth is too deep, the tool shoulder
plunges into the workpiece producing excessive flash. Ouyang
et al. [84] reported that during friction stir welded AA6061
alloy, the shoulder force that was directly responsible for the
plunge depth of the tool pin into the surface of the workpiece
during the plungement. The material flow patterns highly de-
pended upon the geometry of the threaded tool, welding tem-
perature, material flow stress and axial force. Krishnan et al.
[85] studied the mechanism of onion ring formation in the
407
friction stir welds of aluminium alloys and found that the
material flow patterns are highly dependent upon the axial
force. Padmanaban et al. [86] studied the effect of axial force
on mechanical properties of AZ31B magnesium alloy joints
fabricated by friction stir welding. They found that when the
axial force was relatively low, there was a possibility of in-
sufficient stirring at the bottom but with higher axial force,
the weld was sound. It showed that sufficient axial force was
required to form good weld because the temperature during
friction stir welding defined the amount of plasticized mate-
rial and the temperature was highly dependent on the axial
force.
2.3. Joint configuration
The most suitable joint configurations for friction stir weld-
ing are butt and lap joints. A simple square butt joint and lap
joint are shown in Fig. 4. Two sheets of the workpiece with
same thickness are placed together and properly clamped to
avoid the abutting the joint faces from being forced apart dur-
ing the process. During the initial plunge of the FSW tool, the
forces are large so additional care is required to ensure the
position of plates as reported by Padmanaban et al. [52]. The
rotating FSW tool is plunged into the joint line and traversed
along the line when the shoulder of the tool is in intimate con-
tact with the surface of the plates, produced a weld. [87–88].
In case of lap joint, two lapped sheets are clamped on a
backing plate. A rotating tool is vertically plunged through
the upper plate and into the lower plate and traversed along
the desired direction, joined the two plates [89]. Many other
configurations can be produced by the combination of butt
and lap joints. Some other types of joint designs Fig. 5 (edge
butt joint, T butt joint, multiple lap joint, T lap joint, and fillet
408 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
Fig. 5. Other joint configurations for friction stir welding [32].
Fig. 6. Overview of the microstructural zones in FSW joint AZ31 [109].
joint), apart from butt and lap configurations are also useful
in many applications as reported by Vilaça et al. [90] and
Khaled [91].
3. Microstructural evolution
Earlier researchers [56,63,74,101,104,106,109] reported
that FSW modified the microstructure of the base metal
and resulted in the formation of weld nugget/stir zone (SZ),
thermo-mechanically affected zone (TMAZ) and heat af-
fected zone (HAZ) (Fig. 6). Mishra and Ma [32]. Sahu et
al. [110] and Cam [111] cleared that several microstruc-
tural zones, e.g., the weld nugget/stir zone (SZ), the thermo-
mechanical affected zone (TMAZ), and the heat affected
zone (HAZ), are generated during the FSW process and ev-
ery zone exhibits different microstructural characteristics, in-
cluding grain size, dislocation density, and residual stress as
well as precipitate size and distribution. These microstruc-
tural changes in various zones have a significant effect on
post-weld properties of the joint. Therefore, it is important
for investigators to evaluate the microstructure of FSW joint.
3.1. Stir zone
During friction stir welding, plastic deformation and fric-
tional heating results in the generation of a recrystallized
fine-grained microstructure in the stir/nugget zone. Under
some FSW conditions, onion ring structure was observed in
the nugget zone [85,112,113]. However, some investigators
[52,97,103,104,106,114] reported that the small recrystallized
grains of the nugget/stir zone contains the high density of
sub-boundaries, sub-grains, and dislocations. The interface be-
tween the recrystallized nugget/stir zone and the base metal
is relatively diffuse on the retreating side of the tool, however
quite sharp on the advancing side of the tool. Table 4 presents
the grain sizes reported in the previous literature with the sub-
strate materials, tool geometries and welding parameters used
to weld various grades of the magnesium alloys.
3.2. Thermo-mechanically affected zone
As reported in existing literature
[40,56,63,74,101,104,109,115–124], there is the forma-
tion of a transition zone—thermo-mechanically affected zone
(TMAZ) between the parent material and the nugget/stir
zone (SZ) during the fabrication of weld joint by FSW.
Liu [125] and Czerwinski [126] stated that the TMAZ
experiences both temperature and deformation during FSW
process. The TMAZ is characterized as a highly deformed
structure zone. The elongated grains of parent metal were
deformed in an upward flowing pattern around the stir zone.
Due to insufficient deformation strain, the recrystallization
did not occur in this zone. Kouadri-Henni et al. [114] also
reported that the welded zone is composed of two parts:
(i) Transition region (TMAZ) and (ii) Stir zone. In the
TMAZ magnesium grains presented an elongated shape due
to plastic deformation during FSW. They observed that a
deformed grain structure consisting of sub-grains is formed
just outside the stir zone in the TMAZ. The deformation of
the grains increased with decreasing distance from the SZ.
The grain size in the TMAZ is coarser than that in the stir
region, following a grain size gradient, because of insuffi-
cient deformation and thermal exposure. These observations
confirmed by the distribution of grains size.
3.3. Heat-affected zone
Beyond the TMAZ, there is a heat-affected zone (HAZ)
which experiences a thermal cycle but does not undergo any
plastic deformation. Esparza et al. [127] reported that In the
FSW process, the HAZ is a zone where the material experi-
ences no plastic deformation. The metal was neither stirred
by the pin nor rubbed by the shoulder but was influenced by
the heat of welding, leading to some microstructural changes.
4. Texture evolution
The strength, formability, ductility and corrosion resistance
are highly influenced by texture of the material. The FSW
joint consists of nugget/stir zone, TMAZ, HAZ and base ma-
terial with different thermo-mechanical chronicle. During the
FSW process, the plastic deformation in the material occurs
at the elevated temperatures and preferential orientation or
texture evolution is possible in SZ and TMAZ of the welded
joint [109]. As texture is strongly affect the mechanical prop-
erties of the material, the investigation of the crystallographic
 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416 409

Table 4
Summary of substrate materials, tool geometries, welding parameters and grain size of FSW Mg alloys.

Work piece Plate Thickness Tool Geometry Rotational Speed Welding Speed Grain Size μm Reference
material
AZ31 Mg alloy 8 mm Conical threaded 800–1600 rpm 120 mm/min 6–20 [103]
AZ31 Mg alloy 6 mm Cylindrical threaded 1600 rpm 600 mm/min 9.8 [133]
AZ31–O Mg 2 mm Concave shoulder, threaded 600–1400 rpm 200–2000 mm/min 1.66–5.15 [97]
alloy tool pin
AZ31B Mg alloy 6 mm Straight cylindrical, Tapered 1600 rpm 0.67 mm/s 6.3–11.1 [52]
cylindrical, Threaded
cylindrical, Triangular and
Square
AZ31B-H24 Mg 2 mm Left-hand thread and 1000–2000 rpm 5–30 mm/s 5.4 ± 2.2 [129]
alloy right-hand thread
AZ31B-H24 Mg 4.95 mm – 1000 rpm 2 and 4 mm/s 9 [130]
alloy
AZ31B-H24 Mg 4.95 mm – 500–1000 rpm 1–4 mm/s 8.5–9.3 [131]
Alloy
AZ31B-H24 Mg 2 mm Scrolled shoulder 1000 rpm and 10 mm/s or 20 mm/s 7.4–9.5 [37]
alloy 1500 rpm
AZ31B-H24 Mg 2 mm Scrolled shoulder, 2000 rpm 5 - 30 mm/s 3.7–5.5 [106]
alloy Cylindrical threaded
AZ31B-O Mg 5 mm Left hand threaded tool pin 1200–1950 rpm 40–60 mm/min 9 [95]
alloy
ZK60 and AZ31 6 mm Cylindrical threaded 800 rpm 100 mm/min 8.7 (AZ31 side) [134]
Mg alloys and 2.7 (ZK60
side)
AZ31 and AZ91 3 mm Tapered pin 1400–1800 rpm 25–100 mm/min 6.5 ± 6.8 [94]
Mg alloys
AZ91 Mg alloy 5 mm Cylindrical, Triangle, Square 710–1400 rpm 12.5–63 mm/min 9–32 [135]
AZ91 Mg alloy 3 mm – 100–1400 rpm 80–200 mm/min 2 [114]
AZ91 with CaO 4 mm – 1250 rpm 32 mm/min 1–2 [128]
AZ91C Mg alloy 8 mm Square pin 800–1600 rpm 40 mm/ min 14 (FSW) and 8 [105]
(SFSW)
AZ91D Mg alloy 3 mm Tapered cylindrical threaded 1025–1525 rpm 25–75 mm/min 7–21 [104]
AZ91D Mg alloy 4 mm – 115 - 377 rad/s 32 and 187 mm/min 7–19 [132]

orientations arising from the FSW process has been becom-
ing an emerging research area of interest. For FSW of Mg
alloys, the local texture developed in the joints due to the
critical material flow driven by the rotating tool which affect
the mechanical performance. Some research reported that the
initial texture not much affected the final microstructure and
texture in the nugget zone (NZ) [168], different texture dis-
tributions formed in the thermo-mechanically affected zone
(TMAZ) exerts an influence on the mechanical and fracture
behavior of the joint [169]. Some texture studies of FSW mag-
nesium alloys have been reported [109,131,137,149,168–181].
Mironov et al. [96] reported that the AZ31 Mg alloy base
material had a bimodal microstructure consisting of relatively
coarse elongated grains and a minor fraction offine equiaxed
grains. They found that some of the coarse grains contained
lenticular-shaped {101̅2} twins presumably originating from
the prior hot extrusion. The texture was dominated by a mod-
erate {hkil} < 1210> fiber orientation . In the stir zone,
significant grain refinement took place and the {0001} <
uwtv > B-fiber texture became predominant. The microstruc-
ture and texture of the base material and the material in the
central part of the stir zone, higher-resolution EBSD maps
and (0001) and (112̅0) pole figures are shown in Fig. 7. The
formation of this texture is also typically reported in friction-
stirred magnesium alloys [114,131,137,149,172,176,180,181].
Chowdhury et al. [109] reported that AZ31B-H24 Mg alloy
contained a strong crystallographic texture with basal planes
(0002) largely parallel to the rolling sheet surface and ˂112̅0˃
directions aligned in the rolling direction (RD). But, After
FSW the basal planes in the SZ were slightly tilted toward
the TD determined from the sheet normal direction (i.e. top
surface) and also slightly inclined toward the RD determined
from the transverse direction (i.e. cross section) due to the
intense shear plastic flow near the tool pin surface. The pris-
matic planes (101̅0) and pyramidal planes (101̅1) formed fiber
textures. Yang et al. [170] reported that during FSW of Mg–
3Al–1 Zn alloy, the shoulder size did not influence the texture
modification induced by FSW in the nugget and weaken the
{0002} texture in the TMAZ so that fracture was occurred
in the nugget. Commin et al. [137] reported that AZ31 hot
rolled base metal, the {0002} basal plane normal was par-
allel to the sample normal direction. The shoulder diameter
13 mm did not induce such large modification and the frac-
ture was located in the TMAZ but in the 10 mm shoulder
diameter sample, the strong {0002} texture was modified by
the welding process. The basal plane progressively oriented
perpendicular to the welding direction when approaching the
nugget zone. Liu et al. [133] reported that sudden change of
410 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
Fig. 7. EBSD orientation maps and 0001and 11̅20 pole figures illustrating microstructure and texture in (a) base material, and (b) central part of stir zone
[96].
texture at the stir zone (SZ)/transition zone (TZ) interface and
different twinning action between the TZ and SZ-side have an
impact on fracture behavior of bending samples. The effect of
textural variation on fracture behavior in bending is highly de-
pendent on the local stress state. Park et al. [149] reported that
the heterogeneous basal plane texture in friction-stir-welded
AZ61 Mg alloy in the fracture region caused the preferen-
tial plastic deformation and eventually. Here, the major issue
to recognize is the nucleation of new grains and continuous
deformation influence the final texture of the material joint
during FSW. It is essential to distinct the effect of the de-
formation by tool shoulder through the forging action when
the tool pin has passed. The deformation under tool shoulder
is expected to influence the final texture considerably and it
enhances a shear deformation component to the recrystallized
volume processed by the tool pin at lower temperature.
5. Residual stresses
Although FSW is a solid-state joining process which pro-
duces low-distortion welds of high quality, significant levels
of residual stresses can be present in the weld after fabrication
[136]. Commin et al. [97] reported that the magnesium alloy
usage has been limited due to its active chemical properties,
high coefficient of thermal conductivity, low melting point,
hot cracking sensitivity, coarse grains and complex resid-
ual stresses in the weld seam after welding. Commin et al.
[137] studied the influence of the microstructural changes
and induced residual stresses on tensile properties of wrought
magnesium alloy friction stir welds and showed that the high-
est tensile residual stresses were obtained in the TMAZ. The
larger tool shoulder led to reducing residual stresses. Actually,
increasing the shoulder size resulted in a higher heat input
and therefore a thermal expansion mismatch reduction during
cooling. Ahmed and Krishnan [138] reported that high-level
residual stresses can occur in weldment due to restraint by
the parent metal during weld solidification. The stresses may
be as high as the yield strength of the material itself. When
combined with normal load stresses these may exceed the de-
sign stresses. The removal of residual stresses takes place due
to the fact that the thermal energy received by the metal al-
lows for grain boundary sliding and removal of metallurgical
defects like dislocations, vacancies and slip planes. The exist-
ing literature showed that the residual stresses induced during
the welding process of materials. In FSW, residual tensile
stress peaks are observed in the TMAZ in the longitudinal
direction and compressive residual stress peaks occured in a
transversal direction in the fusion zone (FZ) or nugget zone.
Kouadri-Henni et al. [139] reported that the FSW process
highly modified the distribution of residual stress in the differ-
ent zones. The HAZ has weak compressive residual stresses
and TMAZ and FZ the residual stresses are tensile in na-
ture. The residual stress profile in TMAZ and FZ showed
two noticeable peaks in the TMAZ whereas the centre of the
FSW has very low tensile residual stresses. Additionally, the
profile was partially non-symmetrical transversal to the weld
and the TMAZ has not the same behaviour on the advancing
side and the retreating side of the weld. The advancing side
of the weld has a higher level of residual stress in compar-
ison with the retreating side. Yan et al. [140] reported that
there are many methods to improve the mechanical proper-
ties of welded joints such as to select the appropriate welding
method, to select the appropriate welding parameters, and to
control the penetration ratio and the correct choice of post
 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
weld heat treatment. Post-weld heat treatment is an effective
way to eliminate the residual stress and to restore the prop-
erty of the welded joints of magnesium alloys and improve
the performance of the joints [141].
6. Mechanical properties
The existing literature of FSW reports that the friction
stir welding results in significant microstructural development
within the stir zone as well as in TMAZ and HAZ. This vari-
ation affects the post-welding mechanical properties. There-
fore, the mechanical properties are reviewed here and are
summarized in Table 5.
6.1. Tensile properties
As reported earlier that joint strength increased with in-
creasing tool rotation speed and decreasing welding speed
[77], but Lim et al. [78] found no significant effect of pro-
cessing parameters on the tensile strength of friction stir
welded AZ31B-H24 alloy. Pareek et al. [142] studied FSW
of AZ31B-H24 magnesium alloy and showed that the tensile
strength increases with increasing rotational speed. Park et al.
[143] also studied FSW on AZ31Mg alloy plates at tool rota-
tion speed 1230 rpm and transverse speed 90 mm/min which
showed lower yield strength and elongation, and slightly
lower ultimate tensile strength (UTS) of the weld. Nakata
et al. [144] studied the optimal processing conditions for FSW
of AZ91D Mg alloy sheet. The higher tensile strength in
the weld was obtained than base material with a rotational
speed between 1240 rpm to 1750 rpm and transverse speed of
50 mm/min. Padmanabham et al. [52] studied the tool mate-
rial effect on the friction stir welding of AZ31B magnesium
alloy. Different tool materials such as stainless steel, high-
speed steel, and armour steel, mild steel and high carbon
steel were used. It was concluded that the joints fabricated
by high carbon steel tool with 66 HRC, threaded pin profile
and a shoulder diameter of 18 mm exhibited superior tensile
properties. Chowdhury et al. [109] reported the strength and
ductility of the AZ31B-H24 Mg alloy after FSW decreased
at all the strain rates, with a joint efficiency lying in-between
about 75 and 82%. A minor increase of yield strength and
ultimate tensile strength with increasing strain rate was ob-
served, while the ductility in the base alloy decreased consid-
erably. After FSW the strain rate dependence of the tensile
properties nearly disappeared within the experimental scatter.
6.2. Hardness
As reported earlier that most commercial magnesium al-
loys are ternary in nature and made up of aluminium, zinc,
thorium and rare earth. In ternary Mg-Al series, aluminium
is the main alloying element which involves AZ (Mg–Al–
Zn), AM (Mg–Al–Mn) and AS (Mg–Al–Si) alloys [13,14].
Mishra and Ma [32], Dickerson et al. [145] and Uematsu et al.
[146] reported in literature that aluminum alloys are of two
types: (i) heat-treatable (precipitation-hardenable) alloys, (ii)
411
non-heat-treatable (solid-solution-hardened). So the hardness
of the magnesium alloy varies with the variation in aluminium
fraction in it. It has been also reported that hardness profile af-
fected by precipitate distribution and/or rather than grain size
in the weld. The hardness value decreased gradually from
about 73 HV to approximately 63 HV in the center of the
SZ through the HAZ and TMAZ of the joints. The presence
of the lowest hardness in the SZ attributed to the dynamic
recrystallization and grain growth. The decrease in the hard-
ness was due to the larger grain size at the higher rotational
rate [129]. Zhang et al. [147] and Xie et al. [148] reported
that during FSW of Mg–Al–Ca and Mg–Zn–Y–Zr magnesium
alloys, large intermetallic compounds (Al2 Ca and Mg–Zn–Y
phases) were broken up and dispersed in the nugget zone, re-
sulted in the significant increase in hardness. So, the hardness
in the nugget/stir zone was substantially higher than the other
zones. But, Park et al. [149] reported that the uniform hard-
ness throughout various zones of the weld of FSW AZ61.
Esparza et al. [150] also found that FSW AM60 weld ex-
hibited almost similar hardness across the whole weld. Xie
et al. [151] reported that ZK60 is a precipitation strength-
ening magnesium alloy and the MgZn2 precipitates in ZK60
magnesium alloy is much finer than Al12 Mg17 particles in AZ
and AM system alloys. So, the hardness of the ZK60 alloy
is mostly governed by the precipitates. The hardness values
within the nugget zone of the as-welded joint found signifi-
cantly lower than those of the base metal and other zones due
to the further dissolution of MgZn2 particles during FSW pro-
cess. In such cases, the precipitate is the dominant factor to
govern the hardness of the nugget zone rather than the grain
size. Singarapu et al. [47] reported that increasing the rota-
tional speed increases the microhardness and then gradually
decreases. They stated two reasons for the improved hardness
of stir zone. (i) the grain size of stir zone is much finer than
the base metal, grain refinement plays a significant role in
material strengthening. (ii) the small particles of intermetal-
lic compounds are also a benefit to hardness improvement.
Further increasing the rotational speed decreases the micro-
hardness due to the high heat generation which causes ma-
terial softening and resulted in a decrease in the microhard-
ness. They reported that the softening of the nugget/stir zone
was the result of coarsening and/or dissolution of strength-
ening precipitates. Sunil et al. [94] studied the joining of
AZ31 and AZ91 Mg alloys by friction stir welding. They
reported that a gradual increase in the hardness from AZ31
base material to AZ91 base material. In the nugget/stir zone,
large variations in the hardness values found due to the com-
bined effect of fine grain structure and the presence of hard
Mg17 Al12 phase along with some regions of AZ31. Solid so-
lution strengthening also contributed toward an increase of
hardness as the nugget zone becomes a supersaturated solid
solution due to the dissolution of more aluminium by reduced
Mg17 Al12 phase. They concluded that the increased hardness
in the nugget zone can be attributed to the grain refinement
and the presence of Mg17 Al12 particles along with solid so-
lution strengthening. Kouadri-Henni et al. [114] reported that
the significant variations (increase or decrease) of microhard-
 412
Table 5
The summarized mechanical properties of FSW Magnesium alloys.

K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416

Workpiece Plate Thickness Base Metal Friction Stir Weld Joint efficiency Reference
Material (mm) (%)
UTS (MPa) YS (MPa) Hardness (Hv) UTS (MPa) YS (MPa) Hardness (Hv)
AZ31 Mg alloy 4 249.5 to 275 155 to 156.3 57 to 60 155 to 255 90 to 130.5 58 to 82 62 to 93 [103,137,153]
AZ31B Mg alloy 2 to 6 215 to 285 171 to 212 69 to 73 96.18 to 269 71.52 to 200 50 to 77 64.12 to 96.7 [40,52,74,129,131,152]
AZ31B-H24 Mg 2 & 4.95 286 to 315 202 to 227.6 73 178 to 250, 99 to 170 63 74 to 83 [23,106,129,130]
alloy
AZ31B-O Mg 5 206 – 50 140.8 to 187.8 – 64.77 68 to 91 [95]
alloy
AZ31 and ZK60 6 ZK60 −349.5 ZK60 −143.9 ZK60 −65 AZ31 ZK60/AZ31 ZK60/AZ31 – – [134]
Mg alloy AZ31 - 297.8 AZ31 - 96.3 - 55 242.2 106.8
AZ31/ZK60 AZ31/ZK60
233.2 103.9
AZ61 Mg Alloy 4 and 6.3 300 250 60 to 65 285 160 55 to 65 114 [149,155]
AZ61A Mg Alloy 6 271 217 70 224 177 84 83 [101]
AZ31 and AZ91 3 AZ31 - 225 ± 12 AZ31 - 195 ± 15 – 183 ± 15 172 ± 9 – – [94]
Mg alloys AZ91 - 197 ± 17 AZ91 −175 ± 10
AZ91 Mg Alloy 5 134 to 139 – 63 to 84 160 to 212.64 111.28 85.41to105 119 [135,156]
AZ91 with CaO 4 – – 90 – – 65 – [128]
AZ91C Mg Alloy 8 210 85 245 Submerged- 90 to110 117 [105]
410 Submerged- 104 Submerged-195
AZ91D Mg Alloy 3 to 6 107 to 220 150 50 to 95 66 to 213 108 to 140 77 to 100 60 to 100 [104,114,132,154]
 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
ness measured in each transition region i.e. BM and HAZ,
HAZ and TMAZ, TMAZ and nugget/stir. The microhardness
in the HAZ, near to the TMAZ zone, is the same as the base
metal and sometimes slightly higher. The presence of pre-
cipitates formed in this zone responsible for augmenting the
microhardness. The microhardness in the TMAZ and in the
nugget/stir is lower than in the base metal, even though the
size of the grains was smaller than the base metal. They ex-
plained that microhardness decreases due to the influence of
the dislocation density, residual stress variations in the weld
and existence of the crystallographic texture. This difference
in microstructure explained by the reduction in the number
of precipitates which leads toward a reduction in the micro-
hardness.
7. Applications
The applications of FSW as well as magnesium
alloy has been reported in earlier published litera-
ture [6,19,21,23,34,35,40,41,45,47,52,63,74,92–95,97–
99,101–103,105,106,108,109,114,128,129,131,132,134–
135,137,139,149,152,155–181] as summarized below:
1. Land Transportation: Engine chassis, wheel rims. Track
bodies, tail lifts for tracks, mobile cranes, body frames,
fuel tankers.
2. Aerospace Industry: Fuel tanks, wings, fuselages, cryo-
genic tank for space vehicles, aviation fuel tanks.
3. Railway Industry: Goods wagons, container bodies, under-
ground carriages and trams.
4. Shipbuilding and Marine Industries: Panels for decks and
floors, helicopter platforms, hulls and superstructures, ma-
rine and transport structures, offshore accommodation,
masts and booms for sailing boats.
5. Construction Industry: Bridges, frames, pipelines, reactors
for power plants.
6. Other Industry Sectors: Refrigeration panels, Motor hous-
ing.
8. Concluding remarks
In this review article current development in FSW process,
microstructure, residual stresses, mechanical properties, and
applications of friction stir welding of Mg alloys have been
addressed. The basic conclusions that can be drawn from this
review article are as follows:
1. Tool geometry is the most influential part of FSW process
development. The tool pin profile, shoulder diameter and
tool material highly influenced the joint quality. The fric-
tion between the tool shoulder and workpiece is the major
component of heating. So, the size of pin and shoulder is
more important than the design features of the tool. The
scrolled shoulder surface also played a significant role in
stirring/blending the material.
2. The FSW process parameter (angle of spindle or tool tilt
with respect to the workpiece surface, target depth and
413
axial force, insertion depth), in addition to the tool rota-
tion speed and traverse speed, plays an important role in
producing sound welds. The material flow patterns highly
depended upon the geometry of the tool pin, welding tem-
perature, material flow stress and axial force. The welding
temperature is dependent on the axial force.
3. There is a lot of scope for research because the joint de-
signs like- edge butt joint, T butt joint, multiple lap joint,
T lap joint, and fillet joint apart from the butt and lap
configurations are also useful in many applications.
4. FSW modified the microstructure of the base metal and
resulted in the formation of weld stir zone (SZ), thermo-
mechanically affected zone (TMAZ) and heat affected zone
(HAZ). Each zone exhibits different microstructural char-
acteristics, including grain size, dislocation density, and
residual stress as well as precipitate size and distribution.
5. During the FSW process, the plastic deformation in the
material occurs at the elevated temperatures and prefer-
ential orientation/texture evolution is possible in SZ and
TMAZ. The texture affects the mechanical properties of
the material.
6. The significant level of residual stresses produced due to
the large deformation during FSW process. The advancing
side of the weld has a higher level of residual stress in
comparison with the retreating side. The HAZ has weak
compressive residual stresses and the residual stresses are
tensile in nature in TMAZ and FZ.
7. The mechanical properties are highly influenced by the
FSW parameters and conditions. The increase in hardness
in the nugget/stir zone is dependent on the grain refinement
as well as the presence of Mg17 Al12 particles along with
solid solution strengthening.
8. The friction stir welding of magnesium alloy has a wide
range of applications in land transportation, aerospace, rail-
way, shipbuilding and marine, construction and many other
industries.
9. Future outlook
1. The mostly different tool is used by individual researchers
and the only inadequate information is available in existing
literature. Earlier published literature reported that a cylin-
drical threaded pin with concave shoulder tool features is
widely used for FSW. But many special profile tools have
also developed which needs to justify.
2. FSW process parameters (tool rotational speed, tool tra-
verse speed, tool tilt angle, axial force, and target depth)
are important to produce sound and defect-free weld joint.
The selection criterion of these parameters needs to gen-
eralize.
3. Generally, butt and lap joint configuration have been
choosing for FSW as reported in published work. But, for
the real implementation of the FSW, researchers need to
be work on other joint designs.
4. The material flow is the very complex phenomenon and
still requires more understanding.
414 K. Singh et al. / Journal of Magnesium and Alloys 6 (2018) 399–416
5. More understanding required about the effect of alloy com-
position and FSW parameters on the thermal stability of
fine-grained microstructure of friction stir welded Mg al-
loys.
6. The residual stresses induced during FSW can be mini-
mized by selecting the appropriate welding parameters and
the mechanical properties can be improved by post weld
heat treatment (PWHT). So the future researchers should
be focused in this domain.
7. The effects of the final deformation by tool shoulder
through its forging action when the tool pin has passed
need more understanding to elaborate the texture develop-
ment.
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