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.

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1. Choi, J.-W., Hino, R., Ushioda, K., Fujii, H., & Lee, S.-J. (2025). Critical review of solid-state welding for Al alloys with high joint efficiency: Friction stir welding vs. linear friction welding. International Journal of Advanced Joining Science, 12(1), 34–68.
2. Lunetto, V., De Maddis, M., Lombardi, F., & Russo Spena, P. (2025). A review of friction stir welding of industrial alloys: Tool design and process parameters. 9(2), Article 36.
3. Khedr, M. (2022). Review on the solid-state welding of steels: Diffusion bonding and friction stir welding. Metals, 13(1), Article 54.
4. Klimpel, A. (2024). Review and analysis of modern laser beam welding methods. Journal of Welding and Joining, 45(3), 201–234.
5. Sadeghian, A., et al. (2022). A review on dissimilar laser welding of steel–copper and other combinations. Composites Science and Technology, 220, 109–128.
6. Costanza, G. (2025). An overview of the working conditions of laser–arc hybrid processes and their effects on steel plate welding. 9(8), Article 248.
7. Acherjee, B. (2018). Hybrid laser–arc welding: State-of-the-art review. Composite Structures, 197, 91–111.
8. Renderos Cartagena, M. A. (2025). Magnetic pulse welding of dissimilar materials: Weldability window for AA6082-T6/HC420LA stacks. 15(6), Article 619.
9. Su, Z., et al. (2025). Research progress of electromagnetic pulse welding. Journal of Advanced Joining Technologies, 7(3), 45–67.
10. Silva, J. J., et al. (2025). Trends and future projections in ultrasonic welding: A bibliometric review. Journal of Manufacturing Processes, 28, 112–130.
11. Yuan, J. (2026). Ultrasonic welding process and strategies for performance improvement in FRTP. Polymer Joining Science, 14(1), 1–25.
12. Li, T. (2025). Advances in mechanism and application of diffusion bonding. Materials Today Communications, 32, 103–119.
13. Subramanian, S. (2025). Current trends and emerging strategies in friction stir spot welding. Crystal Research and Technology, 15(6), Article 556.
14. Klimpel, A. (2024). Modern laser beam welding: Applications and process control. Welding in the World, 68(4), 401–428.
15. Author, A. (2023). Solid-state welding and its applications: A methodological review. International Journal of Welding Research, 10(2), 77–99.
16. I Publisher. (2023). A comprehensive study on friction stir welding: A review. ResearchGate Preprints.
17. Duong, V. T. (2023). Ultrasonic welding technology: A review. International Journal of Research in Engineering and Science, 11(10), 200–204.

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.

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.

1. Choi, J.-W., Hino, R., Ushioda, K., Fujii, H., & Lee, S.-J. (2025). Critical review of solid-state welding for Al alloys with high joint efficiency: Friction stir welding vs. linear friction welding. International Journal of Advanced Joining Science, 12(1), 34–68.
2. Lunetto, V., De Maddis, M., Lombardi, F., & Russo Spena, P. (2025). A review of friction stir welding of industrial alloys: Tool design and process parameters. 9(2), Article 36.
3. Khedr, M. (2022). Review on the solid-state welding of steels: Diffusion bonding and friction stir welding. Metals, 13(1), Article 54.
4. Klimpel, A. (2024). Review and analysis of modern laser beam welding methods. Journal of Welding and Joining, 45(3), 201–234.
5. Sadeghian, A., et al. (2022). A review on dissimilar laser welding of steel–copper and other combinations. Composites Science and Technology, 220, 109–128.
6. Costanza, G. (2025). An overview of the working conditions of laser–arc hybrid processes and their effects on steel plate welding. 9(8), Article 248.
7. Acherjee, B. (2018). Hybrid laser–arc welding: State-of-the-art review. Composite Structures, 197, 91–111.
8. Renderos Cartagena, M. A. (2025). Magnetic pulse welding of dissimilar materials: Weldability window for AA6082-T6/HC420LA stacks. 15(6), Article 619.
9. Su, Z., et al. (2025). Research progress of electromagnetic pulse welding. Journal of Advanced Joining Technologies, 7(3), 45–67.
10. Silva, J. J., et al. (2025). Trends and future projections in ultrasonic welding: A bibliometric review. Journal of Manufacturing Processes, 28, 112–130.
11. Yuan, J. (2026). Ultrasonic welding process and strategies for performance improvement in FRTP. Polymer Joining Science, 14(1), 1–25.
12. Li, T. (2025). Advances in mechanism and application of diffusion bonding. Materials Today Communications, 32, 103–119.
13. Subramanian, S. (2025). Current trends and emerging strategies in friction stir spot welding. Crystal Research and Technology, 15(6), Article 556.
14. Klimpel, A. (2024). Modern laser beam welding: Applications and process control. Welding in the World, 68(4), 401–428.
15. Author, A. (2023). Solid-state welding and its applications: A methodological review. International Journal of Welding Research, 10(2), 77–99.
16. I Publisher. (2023). A comprehensive study on friction stir welding: A review. ResearchGate Preprints.
17. Duong, V. T. (2023). Ultrasonic welding technology: A review. International Journal of Research in Engineering and Science, 11(10), 200–204.