This project will investigate the feasibility of creating coated FSW tools using a novel high energy physical vapour deposition (PVD) process – HiPIMS (High Power Impulse Magnetron Sputtering). Friction Stir Welding (FSW) is an innovative joining process, which uses a rotating, non-consumable tool, which is traversed along the interface of two work-pieces. The process typically provides enhanced weld quality, strength and durability together with reduced energy consumption and environmental impact when compared to conventional fusion welding processes. However, FSW tooling is an extremely demanding environment – high temperature (>700°C), high abrasion and exposure to the reactive effects of freshly exposed metal surfaces – this has limited its commercial application to low melting point alloys, principally aluminium. Through the application of HiPIMS coating, we hope to enable the welding of ‘high-temperature’ materials, such as steel and titanium for high-value industries (e.g. Aerospace & Transport).