A comprehensive review on friction stir additive manufacturing of various structural alloys for aerospace applications

Additive manufacturing’s ability to create intricate and lightweight structures makes it particularly attractive to the aerospace industry. However, challenges associated with fusion-based metal additive manufacturing, such as porosity, inclusions, particle segregation, internal voids, and hot cracking, have prompted the development of alternative processes. One such process is solid-state friction stir additive manufacturing, which integrates friction stir-welding with additive manufacturing techniques. This manufacturing process offers significant benefits over traditional fusion-based metal additive manufacturing methods by eliminating solidification-related defects and producing high-quality, flawless components with superior mechanical properties. These benefits make this technique a promising technology for manufacturing parts from various structural alloys, particularly aluminum and magnesium alloys, for aerospace applications. This study explores the application of friction stir additive manufacturing in producing aerospace components, focusing on aluminum and magnesium alloys. It highlights the process’s advantages, challenges, and potential for future advancements in the industry. Ongoing research and technological progress are anticipated to further enhance its capabilities, paving the way for its broader adoption in aerospace manufacturing.