Abstract: A welded blank assembly includes aluminum-based sheet metal blanks joined by a friction stir weld and an oxide removal zone on a surface of at least one of the blanks. The average thickness of an oxide layer in the oxide removal zone is less than elsewhere along the surface. The weld is at least partially located in the oxide removal zone and is substantially free from oxide remnants. A method of making a welded blank assembly includes removing at least a portion of an oxide layer on an aluminum-based sheet metal blank to form the oxide removal zone, then joining the blanks together at the oxide removal zone with a weld. Oxide regrowth in the oxide removal zone can be minimized and/or inhibited by welding within a pre-determined time after oxide removal, control of the local environment between oxide removal and welding, and/or use of an oxide inhibitor.