Double side friction stir welding (DS-FSW) was used to join TC4 titanium alloy and 2024-T4 aluminium alloy having dissimilar medium-thick plates with a thickness of 8 mm. The microstructure and mechanical properties in medium-thick Ti/Al dissimilar DS-FSW joints were systematically studied. It revealed that the diffusion-type Ti/Al interface was mainly formed when the rotating speed is low. While intermetallic compounds layers were formed at the Ti/Al interface due to the high welding temperature and intense mechanical mixing at a relatively high rotating speed. The maximum tensile strength of medium-thick Ti/Al dissimilar DS-FSW joint is 265 MPa achieved at the rotation speed of 300 rev min–1, which is 58.9% of the base material of 2024-T4 aluminium alloy.
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