The basic principle of Friction Stir welding (FSW) is described and recent applications reviewed, with particular emphasis on aluminium extruded and rolled products. The tool employed during FSW is critical in determining weld quality and reliability, particularly the probe. Probe types developed to-date are described, together with their main areas of application. Recent developments in probes for butt-welding include the Whorl~(TM) and MX-Triflute~(TM) and the form and advantages of these are presented. Lap welding by FSW is more difficult than butt. Flared-Thiflute~(TM) and the A-Skew~(TM) tools are currently under development for lap welding and show great promise in overcoming these difficulties.
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