Methods for improving joint strength of friction stud welded AA5083 alloy joints

•The joint strength of AA5083 friction stud welding was investigated.•Joints with flat weld faying part of work side did not have the base metal fracture.•The initial oxide film on weld faying part of work side was not extruded as flash.•The suitable weld faying part of work side was suggested as the groove shape.•The welding condition for obtaining the sound friction stud joint was established.