Solid-state friction stir welding is a joining technology that allows alloys that are difficult to fuse using traditional fusion methods to be joined. Structures that are not welded are more expensive and heavier, whereas those that are welded are less expensive and lighter. They have benefited from their application due to the difficulty of joining high-strength aerospace aluminium alloys and other metallic alloys using traditional fusion welding. Friction Stir Welding (FSW) produces precipitation-strengthened aluminium alloys with a variety of microstructures and mechanical properties. The chemical composition of an alloy has an impact on its final and initial microstructure. These variables have a significant impact on the weld microstructure and strength, in addition to welding parameters, thermal cycle and the use of auxiliary cooling systems, tool geometry and thickness. FSW, a new green solid state joining method, was used to join high-strength aerospace aluminium alloys.

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