A comprehensive review on pre- and post-forming evaluation of aluminum to steel blanks via friction stir welding

Tailored blanks of aluminum and steel have increasing applications in recent years. In less critical section of a parts where it is not necessary to use high strength steel but requires lightweight, aluminum provides a reliable substitute. As a promising alternative to join aluminum and steel, friction stir welding has been studied extensively. This review paper emphasizes on the evaluation of pre- and post-forming of friction stir welded blanks and manufacturability issues during metal forming. Upon selection of appropriate parameters to obtain a successful weld, quality and performance are reviewed. The necessity and effect of post-welding heat treatment on heat treatable and non-heat treatable weld joint are discussed. Following, evaluations of pre and post-forming are presented, including mechanical and microstructure characterization as well as formability of the joint using limiting dome height test and springback via v-bending and twist forming. This article concludes important aspects in heat treatment and forming of friction stir welded aluminum and steel blanks.