Abstract
<title>Abstract</title> <p>This review synthesizes the current state of numerical simulation in friction stir welding (FSW) of dissimilar materials, with a particular focus on aluminum-polymer hybrid joints. The rapid expansion of this field, driven by the demand for lightweight, high-performance, and environmentally sustainable components in modern transportation sector, necessitates a rigorous understanding of the complex thermomechanical phenomena inherent to dissimilar systems. Therefore, the present study combines bibliometric mapping with a systematic analysis of Scopus-indexed literature from the past two decades. The analysis delineates the evolution of numerical modeling strategies, identifies key process parameters, and elucidates the thermomechanical fundamentals that govern joint performance. The present study employs an integrated approach, incorporating bibliometric insights, systematic reviews, and critical syntheses, to provide a comprehensive perspective on thermomechanical simulation in dissimilar FSW. The investigation highlights and analyzes the interplay between phase differences aluminum-polymer, thermomechanical behavior, and numerical convergence. The investigation further proposes optimization pathways that enhance accuracy and reliability while mitigating computational demands. This work provides a comprehensive reference for researchers and practitioners seeking to advance the predictive modeling and process optimization of aluminum-polymer FSW joints.</p>