Abstract:Inclusion of foreign bodies is a typical kind of defect in friction stir welding. The included foreign bodies must be eliminated before performing the joint repairing. By using some fused material, or that one in solid-state, some additional material with the same volume as the removed one must be compensated into the eliminated area in the joint. This process is cumbersome, and would bring in some elements which is not existing in the base material. Furthermore, the thermal treatment induced by the fusion in the joint which need to repair would affect the microstructure in the joint. And, it would weaken the strength of the repaired joint. All above are the shortages in existing repairing methods. In this paper, we proposed a dual-pass friction stir welding method, which can repair the joint after removing inclusion of foreign bodies.Without additional material addition, this method can produce the repaired joint that has the same strength as the original one. And it is convenient in application. Especially, the repaired joint has improved elongation.It can be conclude that the proposed repairing method is practical, and has a great application prospect. It has been proved by experiments that the proposed method can make a repairing joint with the same strength as the original one.