Abstract
The paper describes and classifies defects in aluminum joints made using refill friction stir spot welding (RFSSW) technology, which has potential for replacing riveting as a default joining technology in aviation. Three defect groups were distinguished: at the sleeve-plunger interface, between the sheets and in the joint axis. The failure modes by fracture around a weld in the top and the bottom sheets, by rupture between the sheets were presented. The progression of defects at the sleeve-plunger interface due to deteriorating process conditions was shown. The RFSSW joints were compared to the riveted joints applied in the actual airplane structures.
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