Refill Friction Stir Spot Welding (RFSSW) produces a solid-state lap joint between sheet metals, preferably aluminum alloys, without leaving any exit holes in the materials. This process was derived from Friction Stir Spot Welding (FSSW). RFSSW has been demonstrating a potential for replacing conventional joining techniques for providing better joining strength and better corrosion resistance. The goal of the research is to study distortion of Aluminum Alloy 6013 and Aluminum Alloy 2029 welded together. The experimentation involves two stages. In Stage 1, the objective is to find the optimum welding parameters for joining AA 6013 and AA 2029 through a method of Design of Experiments, where single-spot-weld coupons were produced and experimented. In Stage 2, by using the best optimum welding parameter obtained in Stage 1, the objective is to produce 10-spot coupons of AA 2029 and AA 6013 with and without air cooling along with 5 different joining sequences.