In this paper, the influence of friction stir welding process parameters and impact of tool geometry on the microstructural characteristics and tribological properties of AZ80A magnesium alloy are experimentally investigated. Tool with three different pin profiles at a constant tool rotational speed ω to feedrate υ ratio were employed. Additionally, detailed experimental measurements are also carried out on the hardness and wear losses of joints. The chemical compositions of fabricated joints are analysed using energy dispersive spectrometry. The taper cylindrical pin profiled tool exhibited sound joints under the 750 rev min− 1/75 mm min− 1 ratio. It is also found that the tool rotational speed plays a more significant role on the microstructural characteristics and mechanical properties of the joints, compared to feedrate.
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