By using a low rotation rate of 200 rpm with additional water cooling, a friction stir welded (FSW) joint with equal fatigue strength to the base material (BM) was obtained in 5083Al-H19 rolled plates due to the significantly decreased softening and the residual stress effect. Though the hardness value in the heat affected zone (HAZ) was a little lower than that of the BM, the decreased tensile effect of the residual stress in the HAZ greatly improved the fatigue performance, which was even higher than that of the BM, so the final fracture occurred at the BM. This study provides an effective strategy to enhance the fatigue performance of the FSW joints.
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