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Metal-polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal-polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal-polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal-polymer joint quality that have been reported in the literature.

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures