Friction stir welding (FSW) is a solid-state welding method that involves joining two
workpieces by applying pressure and significant plastic deformation close to their
melting temperatures. The impact of rotation speed, travel speed, axial force,
maximum temperature, and tool wear in the friction stir welding (FSW) process is
significant. The present study examines the impact of three specified variables on the
maximum temperature, ultimate tensile strength (UTS), and tool wear of friction stir
welding (FSW) of 6063-T6 and 6060-T6 alloys. Response Surface Methodology (RSM)
has been employed as an auxiliary method. The total amount of material removed
from the tool wear was found to be directly proportional to the rotational speed but
inversely proportional to the travel speed and axial force. The increase in rotation
speed leads to higher tool wear but reduces the surface roughness of the tool. The
findings indicate that the parameter with the most significant impact on the
maximum attained temperature is 1800 rpm rotation speed and 4 mm/min travel
speed, I KN axial force.