Emerging as a transformative technology, Friction Stir Welding (FSW) has proven to significantly enhance the integrity of flange joints, particularly in demanding applications such as offshore and automotive environments. This welding method effectively minimizes defects commonly associated with traditional techniques, ensuring superior mechanical properties in the welded joints. Studies demonstrate that FSW produces weldments with strength values comparable to the base materials, thereby meeting the stringent requirements of industries that operate under harsh conditions—especially offshore structures, where resistance to corrosion and high fracture toughness is paramount. This paper concisely reviews FSW applied to flange joints, focusing on dissimilar material combinations such as aluminum and steel. The influence of tool geometry, process parameters, and joint configurations on weld quality and mechanical properties is discussed.
Furthermore, as industries shift from mass production to mass customization, adopting techniques that streamline manufacturing processes becomes essential. Prospects for FSW lie in its potential application across various materials and complex designs, facilitating innovations such as part consolidation in automotive manufacturing. Ultimately, FSW merits further exploration as a viable solution for enhancing flange joint performance in diverse sectors.Key challenges and future research opportunities in the industrial adoption of FSW for complex flange geometries are also identified