Fundamentals of Electric Resistance Friction Stir Welding of Metals: A Review

Friction Stir Welding (FSW) is a solid-state joining process for welding similar and dissimilar materials with restriction to its use in some low melting point material. Electric Resistance Friction Stir Welding (ERFSW) is a new solid-state joining method for joining high strength materials. The paper presents the fundamental principle of ERFSW processes, impact of the variable parameters on weld quality, basic tool design along with its utilization, tool material and process parameters. The zones of the joint created by heating effect have also been discussed with its micro-structural study in brief. It has been demonstrated that ERFSW of high strength alloy is an emerging technology with numerous commercial applications which may have its great utilization in the field of space and an ignition prone area like mine.