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Different aluminium alloys were joined by friction stir welding (EN AW-5754-H14 to sheets of the same material, extruded profile EN AW-6063-T6 sheets to high pressure die cast EN AC-46000) and characterised by x-ray and microscopy studies, and the measurement of tensile properties and fatigue strength at two load levels. Lap and butt joints in sheet of 3 mm thickness were welded using four different tool designs, and process parameters selected to optimise the joint mechanical properties. Tensile fatigue testing was done at room temperature at a frequency of 20 Hz.

4th International Symposium, 14-16 May 2003, Session 8: Dissimilar & Special Materials 2, Paper 02