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Dissimilar Friction Stir Welding (DFSW) is a process by which different metals such as aluminium, copper, steel, titanium, magnesium, etc., are combined without melting. It is a solid-state joining technique in which workpieces fuse due to thermo-mechanical deformation. The conventional joining of dissimilar materials is not feasible due to several issues such as changes in mechanical, thermal, chemical, and physical properties. In this paper, a comprehensive review of dissimilar FSW techniques presents state-of-the-art research in joining dissimilar materials. Latest developments in joining technologies are reviewed according to the mechanisms of joint formation, i.e. mechanical, chemical, thermal, or hybrid processes. Emphasis is given to essential aspects that determine the quality of the weld, microstructural analysis, weld joint characteristics, joining of dissimilar materials, the welding tools, welding defects experienced during DFSW, and industrial applications.

Dissimilar friction stir welding process-a review