In　this　study,　the　refill　friction　stir　processing　(RFSP)　method　was　utilised　to　repair　a　exit-hole　defect　located　at　the　end　of　the　friction　stir　welding　(FSW)　joints　in　7475　aluminium　alloy　plate.　The　morphology,　macroscopic　defects,　and　mechanical　properties　of　the　repaired　joints　were　investigated.　The　results　demonstrate　that　the　exit-hole　was　successfully　refilled　after　RFSP.　Material　flow　caused　the　refill　voids,　annular　grooves,　and　un-stirred　material　defects.　The　maximum　strength　reached　415　Mpa,　equal　to　105%　of　the　base　defect-free　weld.　The　mechanical　properties　of　repaired　joint　were　largely　influenced　by　the　stir　zone　(SZ)　boundary　and　un-stirred　material　defects.