Patel, SoorajSoorajPatelArora, AmitAmitArora2025-08-312025-08-312024-07-0110.3390/machines120704942-s2.0-85199896988https://d8.irins.org/handle/IITG2025/28854The fabrication of compact heat exchangers with precisely designed micro- and mini-channels is crucial for enhancing the efficiency of thermal management systems. Friction stir channeling (FSC) emerges as a cost-effective advanced manufacturing process to create complex integral channels, offering channel shape and size flexibility. This review article highlights the pivotal role of processing parameters in channel formation and maintaining their integrity, necessitating a comprehensive understanding of material flow dynamics. A rigorous assessment has been conducted on the channel under mechanical stresses, including tension, bending, and fatigue. The paper emphasizes the potential of FSC to revolutionize heat sink applications by exploring the fundamental concepts, governing parameters, ongoing enhancements in tool design, microstructural and mechanical properties, and heat transfer performance.trueadvanced manufacturing | friction stir channeling | heat sink applications | heat transfer performance | material flow | process parameters | tool designReviewhttps://doi.org/10.3390/machines1207049420751702July 20242494reJournal2WOS:001277248000001