The axial force measurement plays an important role in tool designing and identification of its restrictions. Also, it is vital in design of machine mechanism and optimization of welding process parameters. In this study, a friction stir welded butt joint on AA7075-T651 aluminum alloy plate is investigated. With change of some parameters, factors including axial force, mechanical properties, microhardness and weld morphology, are studied. For measuring the axial force, load cell was utilized and a servohydraulic machine was applied to evaluate the mechanical properties. The results show that by increasing the welding speed and in the same rotational rate, the axial force and microhardness increase but the weld appearance quality decreases. However, by increasing the rotational rate in the same welding speed, there is not any certain relationship among the axial force, hardness and weld morphology. Also, by changing the tool tilt angle from zero to 2.5 degrees, the weld morphological feature is enhanced. The results illustrate that the proper change in welding speed and tool rotational rate have great effects on optimizing the welding friction stir process.

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