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By: Mayur Chotaliya, Heena M Patel, Milankumar Pankhaniya, and Parth M Lakum.
1-4 Assistant Professor, Department of Mechanical Engineering, Atmiya University, Rajkot, Gujarat, India.
Abstract
This review examines the quickly changing field of solid-state joining and welding technologies, emphasizing new developments, practical uses, and future research avenues. Strategies that lower heat input, enhance joint integrity, and allow the connecting of sophisticated and dissimilar materials have gained importance within the last ten years. Solid-state techniques are particularly appealing for lightweight alloys used in the automotive and aerospace industries because they reduce melt-related defects and the formation of brittle intermetallic. These techniques include friction stir welding (FSW) and its variations, friction stir spot welding (FSSW), linear friction welding (LFW), magnetic/electromagnetic pulse welding (MPW/EPW), and diffusion bonding. Fusion-based technologies have also evolved: high-power laser beam welding, laser–arc hybrid welding (LAHW), and hybrid processes integrate energy sources to achieve deep, high-quality welds at high speeds while controlling heat-affected zones. Ultrasonic welding has expanded beyond electronics into thermoplastic and composite joining, aided by process control and tooling innovations. Key enabling trends include process hybridization (combining complementary heat/force inputs), process monitoring and closed-loop control (increasing repeatability and enabling automation), and tailored tool and fixture designs for dissimilar-material joining. Emerging applications range from battery pack assemblies and electric-vehicle structures to additive-manufactured component joining and in-space construction. Predictive multi-physics models for microstructure evolution, standardized testing for dissimilar joints, scale-up strategies for novel solid-state methods, and environmentally friendly, energy-efficient industrial implementations are among the urgent research gaps identified by this review, which synthesizes literature from 2018 to 2025 to summarize mechanisms, benefits, limitations, and typical process windows. In order to provide reliable, high-throughput joining solutions for next-generation materials and structures, the review concludes by outlining a future research agenda that focuses on digitalization, sustainability metrics, and interdisciplinary work that integrates materials science, mechanical engineering, and controls engineering.
Keywords: Solid-State Welding, Friction Stir Welding, Hybrid Welding Processes, Dissimilar Material Joining, Laser–Arc Hybrid Welding, Ultrasonic Welding.
Citation:
Refrences:
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