In the present work, 7·8 mm thick AA 2219 rolled plates were successfully joined without keyholes using semiconsumable tools by filling friction stir welding (FFSW). The shoulder further effect was performed to enhance mechanical stir, and mechanical properties were enhanced effectively. The results showed that the bonding interface of AA 2219 bit and keyhole is defect free. The softened region on the advanced side is the weakest part of FFSW joint rather than the bonding interface of the keyhole. The average ultimate tensile strength and elongation are 172 MPa and 11·2%, equal to 90 and 82% of the base weld without defects respectively. Excellent bonding interface and mechanical properties of FFSW joints have been exhibited.
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