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Abstract
In this study, filling friction stir welding was used to remove the exit hole of friction stir welding lap joints made from AA5456 sheets. For this purpose, the exit holes were filled by consumable pins with various geometries and different pin applying methods. Then, the structures and mechanical properties of the resulting joints were investigated. Results showed that the strength of 7% higher than the strength of the joint with the non-filled exit hole, ∼91% of the corresponding defect free joints, is obtainable with this technique. The best results were found by a pin with 11° cone angle, 8 mm diameter and 7 mm length, and with a 6 mm plunge without rotation.