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In this study, RFSSW of similar 5052-0 and 6061-T6 aluminum alloys with various thickness from 1.0 mm to 3.0 mm were performed by using cemented carbide tools. Microstructural features and mechanical properties of the joints produced with optimized welding parameters were investigated. Furthermore, the tool durability was examined by using the developed process monitoring system during welding and automatic cleaning device for the tool. The process monitoring revealed that the tool breakage was caused by an increase of sliding load during the probe moving due to the welded material that stuck between the probe and shoulder. The automatic cleaning of tool could remove most of the welded material stuck on the inside of the shoulder arid the sliding load was significantly decreased. The development of process monitoring system and automatic cleaning device contributed to achieve over 200,000 spots durability with sufficient joint strength without tool breakage.

13th International Symposium, 21-23 May 2024, Session 11: FSSW, Paper 01