Recent Advances in Friction Stir Additive Manufacturing: A Review of Mechanical and Microstructural Performance in Similar and Dissimilar Composites

This review has examined recent advancements, underlying mechanisms, and performance characteristics of FSAM, with particular emphasis on its application to both similar and dissimilar aluminium composites. FSAM demonstrates significant potential in addressing the limitations of conventional fusion-based additive manufacturing, offering enhanced mechanical properties, refined microstructures, and superior interfacial bonding. A systematic evaluation of key process parameters such as tool geometry, rotational speed, and traverse speed reveals their critical role in defect mitigation and structural optimization. Furthermore, the incorporation of reinforcement particles illustrates FSAM’s ability to fabricate composite materials with tailored properties for high-performance applications. Owing to its versatility and capability to fabricate complex, multi-material structures, FSAM stands out as a promising solution for sectors including aerospace, automotive, and biomedical industries. Overall, this study not only consolidates current knowledge but also lays a foundation for continued innovation and optimization in solid-state additive manufacturing technologies.