A review of friction stir lap welding of polymer to metal

Owing to their mechanical qualities, lightweight materials, polymers and metal alloys, such as aluminum and magnesium, are used in a number of industrial applications. In their development, the automotive and aerospace industries have introduced hybrid structures that have led to the need for dissimilar material joints. Due to its solid-state nature, Friction Stir Welding (FSW) technology has found its application in welding dissimilar materials. The current study aims to summarize and review data and findings from previous research and research on lap welds developed for dissimilar materials using Friction Stir Welding. The research investigates and discusses joint formation, microstructure, tensile strength and hardness of metal-polymer joints formed using Friction Stir Lap Welding (FSLW), Friction Lap Welding (FLW) and their variants. It also discusses the research void and future scope of the dissimilar polymer-aluminum joint.