A. K. Shukla, Rensselaer Polytechnic Institute, Troy, NY; W. A. Baeslack III, The Ohio State University, Columbus, OH

Summary: Optimum welding parameters, viz. tool rotation, welding speed, plunge depth and tool design are established for friction stir welding (FSW) 1 mm thick 2024-T3 aluminum alloy by using design of experiments and the effects of these parameters on the weld microstructure and mechanical properties are studied.