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The experiment on API X65 steel was carried out using friction taper plug welding (FTPW) under underwater wet conditions at room temperature. Sound weld formation can be achieved vastly at axial force ranging from 25 to 40 kN and a rotating speed of 7000 rpm. The microstructure of the weld zone consists of lath martensite, upper bainite, granular bainite, polygonal ferrite, and acicular ferrite. The microstructure of heat affected zone (HAZ) mainly consists of lath bainite as well as a bit of lath martensite and granular bainite. The tensile properties of defect-free welds are excellent. The maximum impact energy of the V-notch of bonding area can reach 110 J, which was conducted at 0°C with an error of ±12.5 J. The typical SEM impact fracture morphology presents areas of cleavage, quasi-cleavage, and dimples.

Additive and non-additive T joints were successfully fabricated by stationary shoulder friction stir welding using various welding parameters. No interior defects were observed in all joints by microstructural examination. The fatigue property of both additive and non-additive joints was revealed by four-point bending fatigue test. The microstructure and the stress concentration were investigated at the fatigue crack initiation sites of various T joints. Stress concentration determines the fracture location, and the surface microstructure influences the fatigue property. The stress concentration at the internal corner was evidently lower for additive joint than non-additive joint. The surface of stationary shoulder friction welded joint was characterised by ultrafine grains, which evidently enhanced the fatigue property.

Refill friction stir spot welding (FSSW) is a solid state joining technology recently derived from conventional FSSW. In the present study, refill FSSW was performed in a 0·8 mm thick AA7075-T6 aluminium alloy with varying welding parameters (welding time and plunge depth). The influence of welding parameters on the microstructure and mechanical properties of the weld was investigated in terms of nugget thickness, hardness and overlap shear strength. The microstructural features and fracture mechanism were observed by optical microscopy and scanning electron microscopy. The results indicate that the nugget thickness increases with increasing welding time and plunge depth. Furthermore, melted films observed in the stir zone (SZ) were consistent with a maximum temperature of 470·9°C measured 2·6 mm away from the SZ. The overlap shear strength increases with the increase of weld time and plunge depth due to increasing nugget diameter.