The properties of rotating tool spot joining joints with different rotating tools by the combination between the shoulder diameter and the probe length were investigated in this study. The shoulder diameter of rotating tool affects the tensile strength of the joint significantly. An oversize shoulder diameter decreased the joint strength. The probe length affects more the fracture mode than the joint strength. Interface fracture mode occurred with a rotating tool of short probe length. Plug fracture occurred with a rotating tool of long probe length. Rotary motion of restricted area in the joining interface by the rotating tool was confirmed by displacements of the joining interfaces. Rankin vortex was observed on the joining interface by velocity distribution of rotary motion of joining interface. Al oxide film layers were formed spirally on upper joining interfaces
