Friction stir welding was conducted on 8 mm thick plates made of AA2024-T351 aluminum alloy at tool traverse speeds between 8 and 31.5 mm/min and tool rotational speed between 400 and 800 rpm. Metallographic analyzes and mechanical tests including hardness, tensile, residual stress and fracture toughness tests were carried out to evaluate the microstructural and mechanical properties of the joints as a function of the process parameters. The finite element simulation of the FSW process was also performed using a thermal model. The hardness test results show that the increase in rotational speed or decrease in traverse speed of the tool would cause a decrease in weld zone hardness. The best tensile properties are obtained at rotational/traverse speed ratio between 20 and 32. Also, the longitudinal residual stress profiles were evaluated by employing X-ray diffraction method. The numerical and experimental results showed that the increase in a traverse or rotational speed would increase the residual stress of the weld zone. From the fracture toughness results, it was found that the welding process decreases the joints fracture toughness 18-49% with respect to the base metal.

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