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The purpose of this paper is to evaluate the welding quality of the friction stir joints of Al-SiC with diverse shape of pin geometry tools.

Aluminum matrix composites are gaining unlimited interest and special position in aeronautical industry because of their properties enhanced by the presence of ceramic reinforcement, such as lower density, dimensional stability, exceptional wear and abrasion resistance. Friction stir welding arises as a promising welding process with more advantages than traditional fusion process in the joining of aeronautical components with the utilization of a non-consumable rotational tool shaped by a shoulder and a pin, which can be designed in as many possible geometries. However, the welding quality is not always achieved when varying these pin configurations.

The fabrication and implementation of different pin geometry tools to weld the plates of the material allows to study the behavior of the joints assessing some discontinuities produced in the welds.

To examine the microstructural evolution and its behavior in the different zones of the joint, the practical implication consists in the use of different characterization techniques like the optic microscopy and scanning microscopy, furthermore mechanical test such as the measurement of hardness.

The study of the joints uses different welding tool geometries that were fabricated at prototype scale contribute in the microstructural analysis as well as in the evaluation of the possible discontinuities that are presented.

The purpose of this study is to present a comprehensive review of the fundamental concepts and terminologies pertaining to different types of aluminium metal matrix composites, their joining techniques and challenges, friction stir welding (FSW) process, post-welding characterizations and basic control theory of FSW, followed by the discussions on the research reports in these areas.

Joining of aluminium metal matrix composites (Al-MMC) poses many challenges. These materials have their demanding applications in versatile domains, and hence it is essential to understand their weldability and material characteristics. FSW is a feasible choice for joining of Al-MMC over the fusion welding because of the formation of narrow heat affected zone and minimizing the formation of intermetallic compounds at weld interface. The goal in FSW is to generate enough thermal energy by friction between the workpiece and rotating tool. Heat energy is generated by mechanical interaction because of the difference in velocity between the workpiece and rotating tool. In the present work, a detailed survey is done on the above topics and an organised conceptual context is presented. A complete discussion on significance of FSW process parameters, control schemes, parameter optimization and weld quality monitoring are presented, along with the analysis on relation between the interdependent parameters.

Results from the study present the research gaps in the FSW studies for joining of the aluminium-based metal matrix composites, and they highlight further scope of studies pertaining to this domain.

It is observed that the survey done on FSW of Al-MMCs and their control theory give an insight into the fundamental concepts pertaining to this research area to enhance interdisciplinary technology exploration.