Transportation industries are obliged to address concerns arising from greater emphasis on energy saving and\necologically sustainable products. Engineers, therefore, have a responsibility to deliver innovative solutions that will\nsupport environmental preservation and yet meet industries� requirements for greater productivity and minimised\noperational costs. Aluminium alloys have successfully contributed to meeting the rising demand for lightweight\nstructures. Notable developments in aluminium welding techniques have resolved many welding related problems,\nalthough some issues remain to be addressed. The present study attempts to give an overview of the key factors\nrelated to the formation of defects in welding methods commonly used with aluminium alloys. First, a concise\noverview of defects found in friction-stir welding, laser beam welding and arc welding of aluminium alloys is\npresented. The review is used as a basis for analysis of the relationship between friction-stir welding process\nparameters and weld defects. Next, the formation and prevention of the main weld defects in laser beam welding,\nsuch as porosity and hot cracking, are discussed. Finally, metallurgical aspects influencing weld metal microstructure\nand contributing to defects are tabulated, as are defect prevention methods, for the most common flaws in arc\nwelding of aluminium alloys.
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