The use of (very-)high-strength steels (HSS) and hybrid aluminum-steel structures can markedly contribute towards reaching the goals of the SDGs of the UN and the objective agreed under the Green Deal to reduce net greenhouse gas emissions in the European Union to zero by 2050, while at the same time meeting the continued rise in demand in the constructional and mechanical engineering sector, despite a shortage of skilled workforce in these sectors. However, the full potential of these structures cannot be exploited in fatigue-prone structures using conventional fusion welding techniques. Evolving Friction Stir Welding (FSW) from lab-scale to real-world applications enables the joining of hybrid structures and achieving the required fatigue resistance, thereby helping relevant European industries, such as those in heavy lifting, maritime structures, and infrastructure construction, to regain their position as global market leaders. STIRVIVE develops an efficient FSW process, including the wear-resistant and cost-effective tooling systems. Optimized welding procedures are established, and their demonstration serves as a basis for upscaling the process to real-world applications. A comprehensive fatigue test program, considering both crane and ship applications, including material characterization, static and fatigue tests, enables the validation of the fatigue resistance of FSW joints. To promote FSW as a reliable process, the conceptual design of a portable machine extends the application field to various industries, including retrofitting and repair-welding. STIRVIVE will develop fatigue assessment rules and engineering guidance for the application of FSW, including applicability limits, acceptance gates, and worked examples. Technoeconomic and sustainability analyses evaluate the productivity and life-cycle impacts, supporting future industrial uptake.

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