The heterogeneous structure of polymer and aluminum alloy is an effective way to meet the dual technical indicators of structural performance and lightweight design. Friction stir welding (FSW) is a solid-phase welding technology characterized by low temperature and large plastic deformation. It is basically not affected by the crystal structure and physical-chemical properties of materials and can realize polymer and aluminum alloy-specific materials quality connection. This paper presents a comprehensive review of the current advancements in FSW between polymers and aluminum alloys with a focus on optimizing welding parameters, joint formation, defect identification, and mitigation. The results showed that the most important details are that high rotation speed combined with low welding speed that is beneficial to increase welding heat input, improve joint forming and mechanical properties, and form aluminum riveting structure. Welding defects are the main reason for the low FSW performance of polymer and aluminum alloy heterogeneous structures. To improve the forming and load-bearing capacity of heterogeneous structures, welding tool structure design, surface pretreatment, and welding structure optimization can be utilized.

聚合物和铝合金的异质结构是满足结构性能和轻量化设计双重技术指标的有效途径。搅拌摩擦焊（FSW）是一种具有低温、大塑性变形特点的固相焊接技术。基本不受材料晶体结构和物理化学性能影响，可实现聚合物和铝合金特有材料的品质连接。本文全面回顾了聚合物和铝合金之间 FSW 的当前进展，重点是优化焊接参数、接头形成、缺陷识别和缓解。结果表明，最重要的细节是高转速与低焊接速度相结合，有利于增加焊接热输入，改善接头成型和力学性能，形成铝铆接结构。焊接缺陷是聚合物和铝合金异质结构FSW性能低下的主要原因。为了提高异质结构的成形和承载能力，可以利用焊接工具结构设计、表面预处理和焊接结构优化。