Research progress of energy field-assisted friction stir welding

As an advanced solid-state joining technique, friction stir welding is widely used in fields such as aerospace, where the connection of lightweight high-strength and dissimilar materials poses new challenges for conventional friction stir welding. In recent years, the emergence of energy field-assisted friction stir welding technology has effectively addressed issues such as mismatched plasticization levels in dissimilar material connections and joint embrittlement caused by intermetallic compounds at the interface. This technology also provides new ideas for addressing problems such as high-melting-point material rheological stress, poor plastic deformation ability, serious tool wear, and low welding efficiency. This article reviews the research status of energy field-assisted friction stir welding, including induction heating, laser heating, electrical current heating, arc heating, and ultrasound-assisted heating. The article analyzes the impact of thermal and mechanical energy on joint microstructure and properties from aspects such as process heat generation, material flow, microstructure and property regulation, and coupling mechanism, while also providing prospects for future research directions.