本研究結合傳統摩擦攪拌點銲(Friction Stir Spot Welding)及擠壓扣件(Clinching)技術，建立新一代摩擦攪拌扣件(Friction Stir Clinching)技術應用於鋁合金6061-T6及熱浸鋅低碳鋼板SGCC的點接合。本製程使用兩把刀具(擴孔刀及回填刀)及一座底板模具。擴孔刀用於下試片擴孔成型，回填刀用於上試片材料回填，底板模具用於控制扣件形狀。研究工作分成三部份，首先完成擴孔刀及底板模具設計，再利用田口法及金相觀察，找出合適的擴孔製程參數組合；接著完成回填刀設計，同樣利用田口法及金相觀察，找出合適的回填製程參數組合；最後根據最佳刀具設計及參數組合，完成剪力試片製作，進行靜態拉伸、疲勞測試及金相觀察。研究結果顯示摩擦攪拌扣件的力學特性、顯微組織及破壞模式皆在水準以上，在工業應用上具有可行性。 A new friction stir clinching (FSC) process which combines the "traditional" friction stir spot welding (FSSW) process and the clinching process is used to join aluminum 6061-T6 and hot dip galvanized steel (SGCC) sheets. Two tools, an enlarging tool and a refilling tool, and a die are used in this process. The enlarging tool can deform the lower sheet as a button structure, the refilling tool can push the upper sheet materials back to the button structure, and the die can control the button shape. The research works for the FSC process can be divided into three parts. First, the design of the enlarging tool and die is accomplished. The appropriate processing parameters for enlarging are obtained by the Taguchi method and metallurgical analyses. Next, the design of the refilling tool is accomplished and the appropriate processing parameters for refilling are obtained by the same way. Finally, based on the appropriate processing parameters, the FSC lap-shear specimens are made for the quasi-static tensile tests, fatigue tests, and metallurgical analyses. The experimental results show that the quality of FSC joints, including mechanical performance, microstructure, and failure mode, is above average. The FSC process is feasible for the industry.