A new technique of in situ rolling friction stir welding (IRFSW) has been developed to reduce the residual stress and distortion. It can eliminate the weld flashes and improve corrosion resistance of the FSW seam. A new kind of FSW tool consisting of rolling balls was designed to achieve IRFSW. The residual stresses across the weld were measured by ultrasonic stress measurement experimental installation. The 3?5%NaCl solution was used to corrode the surface of welded joint, and corrosion

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... and potential were determined by an electrochemical analyser. The results shown that the residual tensile stress was reduced, the weld flashes were eliminated, and the corrosion resistance was improved. By applying IRFSW, the reduction of distortion was y34?4% compared with that of conventional FSW joint for aluminium plant with 3 mm in thickness and 300 mm in length.