| Summary: | The aim of this work was to weld thin sheets (2 mm) of Al 7075 in a butt joint configuration using friction stir welding and to identify the appropriate tool geometry and optimum process parameters. Two tools were produced with heat treatable low alloy steel WNr 1.6582/DIN 34CrNiMo6 with a different pin diameter (3 mm and 4 mm). Welding was performed at a range of rotation speeds 1000–2500 rpm and various welding speeds 80–800 mm/min. The tensile strength was measured to evaluate mechanical properties. Results showed that despite the difficulties in friction stir welding thin plates, sound joints can be produced in a repeatable manner, without visible wear on the welding tool. The mechanical strength of the welds showed a decrease (33.75%) over that of the parent material. The mechanical strength was less affected by rotation speed than welding speed and there was a significant decrease in tensile strength compared to the parent material.
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