The peak temperatures during friction stir spot welding of similar and dissimilar aluminium and magnesium alloys are investigated. The peak temperatures attained during friction stir spot welding of Al 6111, Al 2024, and AZ91 are within 6% of their solidus temperatures. In dissimilar AZ91/Al 6111 spot welds the peak temperature corresponds with the α-Mg solid solution and Mg17Al12 eutectic temperature of 437°C. An a-Mg plus Mg17Al12 eutectic microstructure is produced in dissimilar friction stir spot welds when material displaced during pin penetration into the lower sheet material contacts the upper sheet material at the eutectic temperature.
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