Friction stir welding of aluminum alloys is progressing rapidly in industries using aluminum alloys thanks to their compliance to the process requirement, especially relatively low flow stress at intermediate temperatures. Weight reductions can be obtained as well thanks to the possible use of high performance alloys, known as nonweldable before FSW. Finally, in some cases, manufacturing cost reductions by as much as 30% when using FSW are expected in the transport industries. Because of the high potential of the combined use of FSW and aluminum, PECHINEY is engaged in a process of demonstrating both its technical and economical advantages. First, as an aluminum producer, PECHINEY is focused on alloy related issues and its first efforts were focused on characterization and process/alloy interaction understanding. New alloys, especially IS237 and 7040, were identified as particularly suited to FSW, and solutions were found to issues like post-weld corrosion resistance or grain coarsening during post-weld solution heat treatments in 7449 alloy. Secondly, a costing model based on welding speed evolution is developed. It confirms that, due to both process and tools improvements, predicted costs have been divided by 3 during the 5 past years. In order, to better support its customers, PECHINEY has acquired its own FSW machine. It will accelerate the research on processing routes as well as FSW-suited alloys development. Results of metallurgical trials addressing the above issues as well as applications of the cost model will be presented. In addition, some remaining obstacles to widespread implementation of FSW and possible solutions will be discussed.