Abstract: This research focuses at the ways that various friction stir welding (FSW) settings affect the mechanical characteristics of two different aluminum alloys, AA5085 and AA6061. To find the best welding settings for increasing hardness and tensile strength, we used regression modeling, analysis of variance (ANOVA), and the Taguchi L9 orthogonal array. Welding speed mainly impacts hardness, although feed rate greatly impacts tensile strength, according to the results. The peak tensile strength was 125 MPa and the hardness was 62.4 HV, with the optimal settings being a welding axial force of 5 kN, feed rate of 10 mm/min, and speed of 900 RPM. Findings from this study highlight the significance of feed rate and welding speed for achieving strong, defect-free joints for use in the aviation, marine, and automobile sectors. Additional factors that could be investigated in future studies to improve FSW performance include tool geometry, rotational direction, and microstructural features.

Keywords: Friction Stir Welding of Aluminum Alloys, Taguchi Method, ANOVA, Tensile Strength, Hardness

| DOI: 10.17148/IARJSET.2025.12310