Aluminum spot welding is extensively applied in automotive, aerospace, and rail sectors due to its favorable strength-to-weight ratio. While resistance spot welding (RSW) has been the traditional method, its high residual stresses, electrode wear, and limited performance with high-strength aluminum alloys have driven interest toward alternative techniques. Friction stir spot welding (FSSW) offers significant advantages over RSW, linear friction welding (LFW), and hybrid processes, including solid-state joining that minimizes porosity, lower energy consumption, and the elimination of consumable electrodes. Compared to LFW, FSSW requires simpler fixturing and is more adaptable for localized repairs, while offering superior joint surface quality over hybrid laser-assisted methods. Despite these advantages, gaps remain in understanding the influence of process parameters on heat generation, microstructural evolution, and mechanical performance. This review consolidates advancements in tool design, thermal characterization, and weld property for aluminum alloys. It presents comparative insights into temperature distribution, weld strength, hardness variation, and metallurgical transformations reported across studies. By critically synthesizing the earlier works, this work identifies knowledge gaps and potential design improvements, aiming to support the development of more efficient and robust FSSW processes for industrial application.

Unlike mechanical fasteners, joining thermoplastics with friction welding has huge advantages. It has not been many days since welding has been considered a con