Abstract: A method of using friction stir welding to repair weld defects and to help avoid weld defects in intersecting welds and crack-sensitive material, such as 2195 Al—Cu—Li. Intersecting fusion welds in 2195 Al—Cu—Li have shown a propensity to crack both during welding and during proof testing. These cracks have generally been associated with a particular metallurgical structure present in the fusion zone ofVPPA/SPA weldments. HYBRID Friction Stir Overwelding of the initial VPPA/SPA weld from the penetration side is shown to convert the cast microstructure of these VPPA/SPA weldments into a fine grained, dynamically recrystallized microstructure showing higher strength, ductility, toughness, and resistance to intersection weld cracking.