The present study is an attempt to give an outline on detecting discontinuity formation in friction stir welding of 2024 aluminum alloy using X-ray radiography techniques. The concise overview of discontinuities formed during friction stir welding and its appearance in X-ray film has been illus-trated using images. The lack of material inside a weld joint, compared to the filled material in the joint, highly affects the color density of X-ray film. These differences in color density and shape shown on the X-ray film are used to find types and sizes of discontinuities. From the radiographic image, it was found that a decrease in welding speed reduces the shape and size of color intensity that shows a reduction of discontinuity size inside a welding joint. The literature review is used for analysis of discontinuity formation mechanism and its relationship with process parameters. The results obtained from the current study are compared with the literature study, and are found to strongly agree with previous studies.
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