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Abstract
In the present paper, the material flow and intermixing during friction stir spot welding of dissimilar Al2024/Al materials were investigated. The dissimilar materials had quite different strength. The microstructural evolutions taking place during a series of lap and butt welds were observed. The effect of penetration depths, dwell time, rotational speed and tool geometry were systematically investigated. The material flow and formation of the intermixed region were explained by a modified model.