Apart from the functional and economic aspects, the sustainability of any manufacturing process in terms of resource consumption and production of waste has gradually evolved as one of the most important performance metrics in any industrial landscape. Now-a-days, a significant fraction of joining works in automobile and aerospace industries are carried out using friction stir welding (FSW), that make butt or lap joints of similar or dissimilar materials using frictional heat and mechanical mixing caused by a rotating and traversing non-erodible tool. Unlike fusion welding, the strength of the welding in FSW welded aluminium alloys can be very close to that of the parent materials due to the suppression of formation of oxide and voids. Energy consumption and greenhouse gas emission in FSW has been reported to be less by around 40% and 31% respectively as compared to gas metal arc welding. Feasibility of welding aluminium to other metals by FSW bears the promise of lightweight structures, and thus, may lead to improved life of the structures and higher fuel efficiency for vehicles. This paper explores the recent advances in the field of FSW that establish this process as a more sustainable green alternative to the other joining processes.