A comprehensive review of friction stir welding parameters on Ti-6Al-4V alloy microstructure and mechanical properties

Ti-6AL–4 V alloy, is a widely recognised titanium alloy. It is responsible for over half of all applications involving titanium alloys, primarily due to its attractive mechanical and physical properties that make it a highly desirable material. For most applications, the vast majority of working components require permanent joining. The conventional fusion welding of titanium often leads to oxidation losses and increased brittleness. Friction stir welding improves weld quality by preventing heating the metal past its melting point. Despite the fact that Friction Stir Welding (FSW) of Ti6Al4V alloys has advantages over other welding methods, the process parameters have a major impact on the weld microstructure and mechanical properties. In most cases, a defect-free weld with the ideal microstructure can be achieved by selecting the best process parameters, such as the tool material, tool geometry, traverse speed, and rotational speed. This paper briefly reviews Ti-6Al-4 V alloy friction stir welding developments and understandings. Variation in friction stir welding process parameters like tool rotation and translation speed affects weld region microstructure constituents, defects, and mechanical properties. This paper establishes a crucial relationship between process variables, microstructure, defects, and mechanical properties. Summarising and tabulating recent developments for easy understanding and adoption is emphasised.