Abstract
Striving for cleaner production is a sought-after manufacturing philosophy. Friction stir welding (FSW) is a joining technique with par excellence and far less invasive to the environment than even best conventional welding processes. It is energy efficient and free from consumables, affluent and radiations. It is, thus, accepted as a clean welding process that can produce acceptable quality joints. It suffers from some major challenges of defects of its own kind that subject the process open to improvements so as to prove itself a reliable production process. This study presents a holistic characterization of defects commonly found in FSW joints. The finding of the present study reveals that most defects are caused by inadequate heat generation, improper material movement around the pin and inadequate material consolidation behind the pin. The amount of heat generation and material stirring depends on several FSW parameters which may lead to the defect formation, if not selected properly. The results reported in this work are derived from sound literature support and experimentation. Prescriptions are made in the form of characteristics of defects such as likelihood of their location, main responsible parameters along with the recommendations for minimizing them.