Friction stir welding (FSW) consists formation of keyhole at the end phase of the process, which is major defect and needs to be removed. In the present investigation, keyhole of dissimilar friction stir welded Al-Mg joint was repaired by novel technique of pin less tool friction stir repairing. Two different pin less tools having different tool diameters were applied to repair keyhole. Visual inspection, macro structural analysis, microstructure features and mechanical properties are assessed in order to check the successful prevail over of keyhole defect. The results revealed that, keyhole of dissimilar friction stir weld of Al-Mg joint was effectively repaired by pin less tool friction stir repairing. Excellent material mixing was obtained in the repaired area of keyhole. Tensile strength was obtained as 159 MPa that was higher than the dissimilar Al-Mg FSW joint.
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