The present work is aimed to study the friction stir welding and process for the
aluminum alloy 2024-T3, a threaded pin with a diameter of 6 mm and a concaved
shoulder of 18 mm welding tool was used. The single pass friction stir welding
(FSW) process was performed with clockwise tool rotation at different speeds and
variable feeding speeds. The specimens were tested to determine the best ultimate
tensile strength ( ult) and compared with the as received metal. In addition to friction
stir welding (FSW), another phase of welding named friction stir process (FSP) was
used. The best condition out of the FSW variables was selected in order to examine
the double pass welding processes. It was found that the best result is in forward
welding travel and counterclockwise tool rotation. The maximum tensile strength
achieved at friction stir welding process was 72% of the base metal and didn’t
improve in the FSP process. On the other hand, the fatigue endurance limit was
improved for FS weld ment when followed by FSP, where the reduction in fatigue
endurance limit for FSW specimen was 36% while for FSP specimen was 15% of the
base metal.