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Progress and Applications of Additive Friction Stir Welding (AFSW)
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Author(s): Romdhane Ben Khalifa (National Engineering School of Gabes, University of Gabes, Tunisia), Jazia Ben Hmid (National Engineering School of Gabes, University of Gabes, Tunisia)and Ali Snoussi (National Engineering School of Gabes, University of Gabes, Tunisia)
Copyright: 2026
Pages: 24
Source title:
Innovative Welding Methods for Modern Manufacturing
Source Author(s)/Editor(s): Romdhane Ben Khalifa (National Engineering School of Gabes, University of Gabes, Tunisia)
DOI: 10.4018/979-8-3373-1797-7.ch004
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Abstract
Additive Friction Stir Welding (AFSW) is a new solid-state joining technique and an additive manufacturing process that combines the principles of friction stir welding with layer-by-layer material deposition. This paper reviews the basic mechanisms, equipment, and process parameters that support AFSW, highlighting its advantages over traditional fusion-based techniques, including reduced distortion, the elimination of solidification defects, and the joining capability of both homogeneous and heterogeneous materials. AFSW produces very consistent, mechanically sound joints. Control of tool geometry, rotational speed, welding speed, and axial force has been appropriately applied to obtain the desired microstructures with enhanced mechanical properties. The development of automation, real-time process monitoring systems, and hybrid manufacturing technologies have broadened the scope of material use as well as the range of applications for AFSW; major focus industries include aerospace, automotive, and marine.
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