This paper presents the effects of using the refill friction stir spot welding (RFSSW) technique on the mechanical properties and microstructure of aluminum AA5052 and AA6061-T3. Specimens were first prepared from AA5052 sheet of thickness 2 mm and AA6061-T3 of 1.6 mm, for chemical analysis and mechanical tests. Workpieces were then stir spot welded by RFSSW at four rotational speeds (2000, 2500, 3000 and 4000 rpm) using two tool pin diameters (5 and 7 mm) to carry out the tensile shear tests. Microhardness testing was conducted at the best conditions along the cross-section of the welded specimens, as well as microstructure examination. The results of the tensile shear tests manifested that, for AA5052 and AA6061-T3 at the tool rotational speeds 2000 rpm and 3000 rpm, respectively, using a tool pin of 7 mm the ultimate tensile shear force was slightly higher than at other speeds in both diameters of tool pin (5 and 7 mm). However, the microhardness results displayed a W-shape at the best conditions. Finally, the microstructure inspection revealed the morphology of the major zones of the weld joint.

This paper presents a comparison of using different techniques for stir spot welding of Aluminum 2024-T3, which are refill friction stir spot welding (RFSSW), edited (RFSSW-pin) and conventional friction stir spot welding (FSSW), depending on the obtained tensile shear strength property. Specimens were prepared from AA2024-T3 sheet for chemical analysis and mechanical tests. Workpieces were stir spot welded utilizing the above mentioned techniques at four rotational speeds (2000, 2500, 3000 and 4000 rpm) using tool pin diameters (5 and 7 mm) for conducting the tensile shear tests. The microhardness along the cross section of the welded specimens was conducted at the best conditions as well as the microstructure examination. The comparison results revealed that at the rotational speeds (2000 and 4000 rpm) in both cases of tool pin (5 and 7 mm), the ultimate tensile shear force was slightly higher than that for other speeds. However, the ultimate tensile shear force was found higher at 3000 rpm speed with a tool pin 7 mm. The microhardness results manifested a W-shape at the best conditions. Finally, the microstructure examination depicted the morphology of the main zones of the weld joint.